Harbor Freight Tools 94564 User Manual

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Page 1

TRAILER

MODEL 94564

4’ x 8’

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 tting 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

Visit our Web site at http//www.harborfreight.com

TO PREVENT SERIOUS INJURY,

READ AND UNDERSTAND ALL WARNINGS

AND INSTRUCTIONS BEFORE USE.

Copyright© 2006 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 or replacement parts, please call 1-800-444-3353.

Manual Revised 07f

Page 2

CONTENTS

SPECIFICATIONS .................................................................................... 3

UNPACKING ............................................................................................ 3

GENERAL SAFETY RULES .................................................................... 3

Work Area ..............................................................................................................3

Equipment Use and Care......................................................................................4

Service ...................................................................................................................5

SPECIFIC PRODUCT WARNINGS AND PRECAUTIONS ..................... 5

ASSEMBLY INSTRUCTIONS .................................................................. 7

Phase 1: .................................................................................................................7

Phase 2: .................................................................................................................8

Phase 3: .................................................................................................................9

Phase 4: .................................................................................................................9

Phase 5: ................................................................................................................10

Phase 6: ................................................................................................................10

Phase 8: ................................................................................................................13

Phase 9: ................................................................................................................14

Phase 10: ..............................................................................................................16

OPERATING INSTRUCTIONS ............................................................... 17

TIRE INFORMATION .............................................................................. 18

Tire Terminology Glossary ..................................................................................18

Tire Markings ........................................................................................................20

Tire Ination and Load Limit ...............................................................................21

TIRE CARE ............................................................................................. 22

Checking Tire Pressure .......................................................................................22

Steps for Maintaining Proper Tire Pressure ......................................................22

Tire Size ................................................................................................................23

Tire Tread ..............................................................................................................23

Tire Rotation .........................................................................................................23

Tire Balance and Alignment ................................................................................23

Tire Repair ............................................................................................................23

VEHICLE LOAD LIMIT ........................................................................... 24

Steps for Determining Correct Load Limit .........................................................24

INSPECTION, MAINTENANCE, AND CLEANING ................................ 25

PARTS LISTS & ASSEMBLY DIAGRAM ............................................... 26

LIMITED 90 DAY WARRANTY ............................................................... 27

Page 2SKU 94564 For technical questions, please call 1-800-444-3353.

Page 3

SPECIFICATIONS

Maximum Load Capacity 1,740 Pounds Bed Dimensions 4 Feet Wide x 8 Feet Deep Required Hitch Ball Size (not included) 2” Wheel Rim Diameter & Width 12” Diameter x 4” Wide Tire Size & Type 5.30 – 12 / 6 P.R. / Load Range Rating C Wheel Lug Nut Quantity & Torque Requirement Required Tire Air Pressure 80 PSI Per Tire Maximum (Cold) Stop & Tail Light Type #1157 VDC (Clear) Side Running Light Type #1895 VDC (Amber) Ground Clearance 15-1/4” @ “Tongue / 17-1/2” @ Rear / 9-3/4” @ Axle Overall Dimensions 139-1/4” Long x 62-1/4” Wide @ Fenders

Unit Weight (Empty) Approximately 330 Pounds

5 Per Rim 85 to 90 Ft./Lbs.

25-1/2” High @ Top of Fenders 20-1/2” @ Deck Surface

UNPACKING

When unpacking, make sure all the parts and hardware shown on the Parts List/

Hardware List (page 19) are included. If any parts are missing or broken, please call Har-

bor Freight Tools at the number shown on the cover of this manual as soon as possible.

SAVE THIS MANUAL

You will need this manual for the safety warnings and precautions, assembly, operating, inspection, maintenance and cleaning procedures, parts list and assembly diagram. Keep your invoice with this manual. Write the invoice number on the inside of the front cover. Keep this manual and invoice in a safe and dry place for future reference.

GENERAL SAFETY RULES

IMPORTANT SAFETY INSTRUCTIONS

WARNING!

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 dam-

age to the Trailer, property damage, or SERIOUS PERSONAL INJURY.

SAVE THESE INSTRUCTIONS.

Work Area

Keep work area clean and dry. Cluttered, damp, or wet work areas invite injuries.

Keep children away from work area. Do not allow children to play in, climb on or

ride in this product.

Page 3SKU 94564 For technical questions, please call 1-800-444-3353.

Page 4

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 out of

reach of children.

Do not use this product if under the inuence of alcohol or drugs. Read warning

labels on prescriptions to determine if your judgement or reexes are impaired while

taking drugs. If there is any doubt, do not attempt to use this product.

Use eye protection. Wear ANSI-approved safety impact eye goggles when assem-

bling 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 becom-

ing caught in moving parts. If wearing a long-sleeve shirt, roll sleeves up above

elbows.

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.

Equipment Use and Care

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 replace-

ment parts. Only 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 qualied technician.

Use the right equipment 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 product was designed. It will do the job better and more safely at the capacity

for which it was intended. Do not modify this product, and do not use this product

for a purpose for which it was not intended.

Page 4SKU 94564 For technical questions, please call 1-800-444-3353.

Page 5

Service

Equipment service must be performed only by qualied repair personnel. Service

or maintenance performed by unqualied personnel could result in a risk of injury.

When servicing equipment, use only identical replacement parts. Follow instruc-

tions in the “Inspection, Maintenance, and Cleaning” section of this manual. Use

of unauthorized parts or failure to follow maintenance instructions may create a risk

of personal injury.

SPECIFIC PRODUCT WARNINGS AND PRECAUTIONS

To avoid personal injury and/or property damage, do not exceed the Trailer’s maxi-

mum weight capacity of 1,740 pounds (evenly distributed).

Before each use, always examine the Trailer for proper Tire air pressure (maximum

pressure is 80 PSI cold), damaged tail lights, damaged side running lights, loose

bolts and nuts, structural cracks and bends, and any other condition that may affect

its safe operation. Do not use the Trailer even if minor damage appears.

Never allow adults, children, or pets to ride in or play on the Trailer.

Before each use, always attach the Safety Chain 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.

10.

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.

Prior to using the Trailer, make sure to read and understand all instructions and

safety precautions as outlined in the owner’s manual for the towing vehicle. 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.

Make sure the Coupler and the vehicle’s ball hitch (not included) are of equal mat-

ing size (2”) and are rated equal to or greater than the weight of the Trailer and its

payload.

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 elec-

trical current.

Whenever possible, park the Trailer on a at, level, paved, surface and chock both

Tires to keep the Trailer from accidently moving.

Page 5SKU 94564 For technical questions, please call 1-800-444-3353.

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11.

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, the Trailer could jackknife, causing severe damage to the Trailer and towing vehicle.

12.

13.

14.

15.

Maintain labels and nameplates on the Trailer. These carry important information. If unreadable or missing, contact Harbor Freight Tools for a replacement.

Reporting safety defects: If you believe your Trailer has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Trafc 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 nds that a safety defect exists in a group of

vehicles, it may order a recall and remedy campaign. However, NHTSA can not become involved in individual problems between you, Harbor Freight Tools, or the manufacturer. To contact NHTSA, you may either call the Auto Safety Hotline tollfree 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.

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.

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.

16.

This Trailer must be securely connected to the towing vehicle before loading.

Page 6SKU 94564 For technical questions, please call 1-800-444-3353.

Page 7

Phase 1:

FRONT END OF

FIGURE A

Parts Needed

Part # Description Qty.

1FL Front Left Side Rail 1

1FR Front Right Side Rail 1

2A Cross Member 1 2B Cross Member 2

A M10 x 20 Bolt 8

I M10 Nylon Nut 8

ASSEMBLY INSTRUCTIONS

Lay out the Front Left Side Rail (1FL), Front Right Side Rail (1FR), one Cross Member (2A), and two Cross Members (2B). Assemble these parts, using the M10 x 20 Bolts (A) and M10 Nylon Nuts (I). (See Figure A.)

Page 7SKU 94564 For technical questions, please call 1-800-444-3353.

Page 8

Phase 2:

FIGURE B

Parts Needed

Part # Description Qty.

3L Left Connecting Rail 1 3R Right Connecting Rail 1

4 Angle Iron 2 5 T-Plate 1 6 Coupler Base 1

9 L-Latch 2 A M10 x 20 Bolt 8 B M10 x 25 Bolt 6 F M14 x 30 Bolt 2

I M10 Nylon Nut 14

J M14 Nylon Nut 2 R 3mm R-Pin 2

Attach an Angle Iron (4) to the Front Left and Front Right Side Rails (1FL, 1FR) and Cross Member (2B), using the M10 x 20 Bolts (A) and M10 Nylon Nuts (I). (See Figure B.)

Attach the Left and Right Connecting Rails (3L, 3R) to the Cross Member (2B), using the L-Latch (9) and 3mm R-Pin (R). Then attach the Left and Right Connecting Rails to the Angle Irons (4), using the M14 x 30 Bolts (F) and M14 Nylon Nuts (J). (See Figure B.)

Attach the Coupler Base (6) to the Left and Right Connecting Rails (3L, 3R), using the M10 x 25 Bolts (B) and M10 Nylon Nuts (I). Then attach the T-Plate (5) under the Left and Right Connecting Rails, using the M10 x 25 Bolts (B) and M10 Nylon Nuts (I). (See Figure B.)

Page 8SKU 94564 For technical questions, please call 1-800-444-3353.

Page 9

Phase 3:

FIGURE C

Parts Needed

Part # Description Qty.

1RL Rear Left Side Rail 1

1RR Rear Right Side Rail 1

2B Cross Member 3

A M10 x 20 Bolt 10

I M10 Nylon Nut 10

Parts Needed

Part # Description Qty.

A M10 x 20 Bolt 2

I M10 Nylon Nut 2

FIGURE D

Lay out the Rear Left Side Rail (1RL), Rear Right Side Rail (1RR), and three Cross Members (2B). (See Figure C.)

Assemble the Rear Left Side Rail (1RL), Rear Right Side Rail (1RR), and three Cross Members (2B), using the M10 x 20 Bolts (A) and M10 Nylon Nuts (I). (See Figure C.)

Phase 4:

Assemble the front portion and rear portion, using the M10 x 20 Bolts (A) and

M10 Nylon Nuts (I). (See Figure D.)

Page 9SKU 94564 For technical questions, please call 1-800-444-3353.

Page 10

Phase 5:

FIGURE E

12L

1FL

Parts Needed

Part # Description Qty.

12L Left Spring Hanger 1 12R Right Spring Hanger 1

B M10 x 25 Bolt 6 C M10 x 30 Bolt 2 H M10 x 30 Carriage Bolt 4

I M10 Nylon Nut 12

FIGURE F

Parts Needed

Part # Description Qty.

14 Spring Plate 2 15 Spring 2 16 Axle 1 17 U-Bolt 4 22 Fender 2 23 Fender Seat 2

Parts Needed

Part # Description Qty.

A M10 x 20 Bolt 8 G M14 x 80 Bolt 4

I M10 Nylon Nut 16 K M14 Hex Nut 4 S 3mm Cotter Pin 4

With assistance, turn the frame upside down.

Attach the Left Spring Hanger (12L) to the Front Left Side Rail (1FL), using the M10 x 25 Bolts (B) and M10 Nylon Nuts (I). (See Figure E.)

Attach the Right Spring Hanger (12R) to the Front Right Side Rail (1FR), using the M10 x 25 Bolts (B) and M10 Nylon Nuts (I). (See Figure E.)

Attach the Left Spring Hanger (12L) to the Rear Left Side Rail (1RL), using the M10 x 30 Bolts (C), M10 x 30 Carriage Bolts (H), and M10 Nylon Nuts (I). (See Figure E.)

Attach the Right Spring Hanger (12R) to the Rear Right Side Rail (1RR), using the M10 x 30 Bolts (C), M10 x 30 Carriage Bolts (H), and M10 Nylon Nuts (I). (See Figure E.)

Phase 6:

Attach a Fender Seat (23) to the Left Spring Hanger (12L), using the M10 x 20 Bolts (A) and M10 Nylon Nuts (I). (See Figure F.)

Attach the remaining Fender Seat (23) to the Right Spring Hanger (12R), using the M10 x 20 Bolts (A) and M10 Nylon Nuts (I). (See Figure F.)

Page 10SKU 94564 For technical questions, please call 1-800-444-3353.

Page 11

NOTE:

Periodically, grease the Seal (99)

on the backside of the Hub (18)

FIGURE G

Parts Needed

Part # Description Qty.

18 Hub 2 19 Tire/Wheel Assy. 2 20 Bearing 2 21 Dust Cap 2 31 Grease Fitting 2

L M12 Lug Nut 10

M M20 Castle Nut 2

O 20 Flat Washer 2

T 4mm Cotter Pin 2

Attach a Fender (22) to the left Fender Seat (23), using the M10 x 20 Bolts (A) and M10 Nylon Nuts (I). (See Figure F.)

Attach a Fender (22) to the right Fender Seat (23), using the M10 x 20 Bolts (A) and M10 Nylon Nuts (I). (See Figure F.)

On each side, place a Spring (15) on the Spring Hangers (12L, 12R) with the spring eyes forward. Insert an M14 x 80 Bolt (G) through the Springs, and secure the Bolts with M14 Nuts (K) and 3mm Cotter Pins (S). (See Figure F.)

Place the Axle (16) on top of the Springs (15). Place a Spring Plate (14) under the Springs. Insert a U-Bolt (17) through the Axle, Springs, and Spring Plates. Secure the Axle with M10 x 20 Bolts and M10 Nylon Nuts (G) screwed onto the U-Bolts. (See Figure F.)

Phase 7:

IMPORTANT: Whenever a Hub (18) on a new Trailer requires assembly (or if a Hub is disassembled for maintenance) the following procedures MUST be followed:

Using a suitable solvent, thoroughly clean the Hub (18), Bearings (20), Castle Nut (M), Dust Cap (21), and the rest of the parts of the Hub Assembly of all grease, dirt, metal shavings, and all other foreign objects. These parts must be cleaned, even if they are new or appear to be clean. (See Figure G.)

Allow all parts to dry completely.

Make sure your hands are clean and the bearing packer (not included) is clean.

Place fresh, clean bearing grease in the bearing packer.

Page 11SKU 94564 For technical questions, please call 1-800-444-3353.

Page 12

With the grease-lled bearing packer in one hand and the Bearings (20) in the

other, press the Bearing into the grease, forcing the grease inside the slots in grease, forcing the grease inside the slots in the Bearing. Continue doing this until every slot in the Bearing is completely full of grease. (See Figure G.)

Finish assembling the Hub Assembly as explained below, making sure not to

get dirt or debris on any part of the assembly.

Note: Use a lug wrench (not included) to tighten the M12 Lug Nuts (in a “star” pattern) to

Carefully slide the Hubs (18) over the spindles at each end of the Axle (16). (See Figure G.)

Insert the Bearings (20) and Flat Washers (O) on the spindles. Screw an M20 Castle Nut (M) tightly onto each spindle. Then back the Castle Nut off slightly so that the Hubs can just move freely. (See Figure G.)

Insert a 4mm Cotter Pin (T) through the M20 Castle Nut (M) and hole at the end of each spindle, and spread the Cotter Pins. (See Figure G.)

Fill the Dust Caps (21) with bearing grease. Then, press each Dust Cap onto the Hubs (18). (See Figure G.)

Grease each Grease Fitting (31) located on the backside of each Hub (18). (See Figure G.)

Install a Tire/Wheel (19) assembly on each Hub Set (18). Then, secure the Tire/ Wheel assemblies, using the M12 Lug Nuts (L). (See Figure G.)

85 to 90 ft-lb. (See Figure G.)

Page 12SKU 94564 For technical questions, please call 1-800-444-3353.

Page 13

Phase 8:

Parts Needed

Part # Description Qty.

7 Coupler 1

8 Safety Chain 1 24 Side Running Light 2 26 Tail Light Bracket 2 27 License Plate Bracket 1

28L Left Tail Light 1

28R Right Tail Light 1

29 Safety Pin 1

A M10 x 20 Bolt 4

D M12 x 40 Bolt 1

E M12 x 90 Bolt 2

N 10 Flat Washer 1

P 4mm Self Tapping Screw 4

Q 2mm R-Pin 1 U M12 Nylon Nut 4 V M12 x 20 Bolt 1

FIGURE H

With assistance, turn the Trailer assembly right side up.

Attach the Coupler (7) to the Coupler Base (6), using the M12 x 90 Bolts (E) and M12 Nylon Nuts (U). Insert an M10 x 25 Bolt (B) downward through the rear hole of the Coupler and Coupler Base and screw on an M10 Nylon Nut (I). (See Figure H.)

Lock the Coupler (7) Trigger, using a Safety Pin (29) and 2mm R-Pin (Q). (See Figure H.)

Attach the Safety Chain (8) to the Coupler (7) with an M12 x 40 Bolt (D) inserted through the center link of the Safety Chain. Then secure the Safety Chain in place, using a Flat Washer (N) and M12 Nylon Nut (U). (See Figure H.)

Assemble the Tail Light Brackets (26) to the rear of the Rear Left Side Rail (1RL) and Rear Right Side Rail (1RR), using the M10 x 20 Bolts (A) and M10 Nylon Nuts (I). (See Figure H.)

REV 07j

Page 13SKU 94564 For technical questions, please call 1-800-444-3353.

Page 14

TAIL LIGHT IL-

RUNNING LIGHT

GROUND (WHITE)

CONNECTOR

YEL-

BROWN

WIRE

(FROM LIGHT)

BROWN

YEL-

RED

BLACK

L.H. STOP &

R.H. STOP & TURN

GREEN

CONNECTOR

WIRE

(FROM LIGHT)

BROWN

WIRE CLIP

GREEN

BROWN

BLACK

RED

FIGURE I

Attach the License Plate Bracket (27) with the Left Tail Light (28L) to the Rear Left Side Rail (1RL), using the M10 x 20 Bolts (A) and M10 Nylon Nuts (I). NOTE: The Left Tail Light has a clear window at the bottom. (See Figure H.)

Attach the Right Tail Light (28R) to the rear of the Right Side Rail (1RR), using the M10 x 20 Bolts (A) and M10 Nylon Nuts (I). (See Figure H.)

Open the Lens of the Side Running Lights (24). Run the Wire Lead of a Side Running Light through the center hole located at the front end of the Front Left Side Rail (1FL). Then attach the Side Running Light to the Front Left Side Rail, using the 4mm Self Tapping Screws (P). (See Figure H .)

Run the Wire Lead of the remaining Side Running Light (24) through the center hole located at the front end of the Front Right Side Rail (1FR). Then attach the Side Running Light to the Front Right Side Rail, using the Self Tapping Screws (P). (See Figure H.)

10.

Re-install the Lens on the two Side Running Lights (24). (See Figure H.)

Phase 9:

Have a qualied service technician install a 4-wire, 12 volt DC Connector in the

trunk area of your vehicle.

Locate the vehicle’s Connector Plug near the Trailer’s Coupler (7) and lay out the Trailer’s Wiring Harness wires. (See Figure I.)

Page 14SKU 94564 For technical questions, please call 1-800-444-3353.

Page 15

Connect the Brown Wire to the vehicle’s Left Tail Light by stripping, wrapping, and taping the Connector Plug. (See Figure I.)

10.

Connect the Yellow Wire to the vehicle’s Left Signal and Stop Light Wire. (See Figure I.)

Connect the Green Wire to the vehicle’s Right Signal and Stop Light Wire. (See Figure I.)

NOTE: Some foreign vehicles may require an adaptor to convert their 5-wire system to a 4-wire vehicle Connector Plug. (See Figure I.)

Attach the White Ground Wire at the plug end of the Wiring Harness to the small hole on the Coupler Base (6) with a 1/4” Tapping Screw (not included). (See Figure I.)

Leave about 18” of wire beyond the Coupler (7). Then lay out the remaining wires along the Connecting Rails (3L, 3R) and Left and Right Side Rails (1FL, 1FR, 1RL, 1RR). (See Figure I.)

Secure the wires to the Connecting Rails (3L, 3R) and Left and Right Side Rails (1FL, 1FR, 1RL, 1RR), using the Clips provided. (See Figure I, Circle D.)

Connect the Wire Lead from the Side Running Light (24) on each side of the Trailer to the Brown Wire of the Wiring Harness, using a Wire Connector. (See Figure I, Circle E.)

11.

12. Left Side Right Side Yellow-Red Wire Green-Red Wire Brown-Two Black Wires Brown-Two Black Wires

Strip about 3/4” of the ends of the Yellow/Brown and Green/Brown wires. (See Figure I.)

Make the following connections (per color code). (See Figure I, Circle C.)

Page 15SKU 94564 For technical questions, please call 1-800-444-3353.

Page 16

Phase 10:

3/4” THICK PLY-

3/8”

CARRIAGE BOLT

3/8”

WASHER

3/8”

LOCK WASHER* 3/8” NUT

3/8”

HARDWARE

PLYWOOD

(NOT INCLUDED)

FIGURE J

To install a Bed for the Trailer, cut two pieces of 3/4” thick plywood (not included)

at 48” x 48”. NOTE: It may be necessary to slightly trim the plywood to t.

(See Figure J.)

Mark 7 locations in each piece of plywood to correspond with the 14 mounting holes located on the front and rear Cross Members (2A, 2B) and Left and Right Side Rails (1FL, 1FR, 1RL, 1RR). Set the plywood aside, and drill the 14 marked locations with a 3/8” bit. Then, replace the plywood on the Trailer frame. (See Figure J.)

Secure the two pieces of plywood to the front and rear Cross Members (2A, 2B) and Left and Right Side Rails (1FL, 1FR, 1RL, 1RR), using 3/8” diameter, rust resistant Carriage Bolts, Washers, Lock Washers, and Nuts (none included). Make sure the bolt heads do not protrude up through the plywood. (See Figure J.)

Page 16SKU 94564 For technical questions, please call 1-800-444-3353.

Page 17

OPERATING INSTRUCTIONS

2mm R-PIN (Q)

SAFETY PIN (29)

HITCH

TRIGGER

COUPLER

(7)

SLOT

HANDLE

ADJUSTMENT

NUT

2”

HITCH

FIGURE K

Only use a 2” Ball Hitch (not included) on the towing vehicle. (See Figure K.)

NOTE: To reduce friction between the 2” Ball Hitch and Trailer Coupler (7), apply a layer of heavy grease over the Ball Hitch. (See Figure K.)

Temporarily remove the 2mm R-Pin (Q) and Safety Pin (29). Then, pull up on the Trigger and lift up on the Handle. (See Figure K.)

Page 17SKU 94564 For technical questions, please call 1-800-444-3353.

Page 18

Tr i g g e r o n locking handle MUST latch in pl ace befor e i n s e r t i n g safety pin.

With assistance, place the Hitch Coupler (7) over the vehicle’s Hitch Ball 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 tting 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. (See Figure K.)

10.

Re-install the Safety Pin (29) and 2mm R-Pin (Q).

Make sure to attach each side of the Safety Chain (8) 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 wiring connector. 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 (24), and Tail Lights (28L, 28R) at least every 100 miles.

Carry emergency ares, and re extinguisher, if required for operation in your state.

Carry extra bulbs and fuses if towing the Trailer at night over long distances.

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 deect 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, 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.

Page 18SKU 94564 For technical questions, please call 1-800-444-3353.

Page 19

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:

•

Curb weight;

Accessory weight;

Vehicle capacity weight; and

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 levelers, 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 distrib-

•

uting 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.

Page 19SKU 94564 For technical questions, please call 1-800-444-3353.

Page 20

Tire Markings

Inner diameter

in inches

Section width

in inches

Load index and

Speed rating*

European tire

certicate*

U.S. DOT tire

identication

number

Tire ply

composition

and materials

used

Maximum

permissible

ination

pressure

Maximum load rating

Trailer

tire

Section width- This number gives the width of the tire in inches. The larger the number, the wider the

•

*Information not required by U.S. DOT

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 rim diameter in

•

inches. (The markings on the example tire diagram show 12. The markings on your tire may differ.)

U.S. DOT tire identication 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.

Load Index Rating Codes

Code Pounds

71 761 72 783 73 805 74 827 75 853 76 882 77 908 78 937

Load index- This is a measurement of how much weight each tire can support. See chart above. (The

•

markings on the example tire diagram show 71. The markings on your tire may differ.) Note: You may

not nd this information on all tires because it is not required by law.

Code Pounds

79 963 80 992 81 1,019 82 1,047 83 1,074 84 1,102 85 1,135 86 1,168

Code Pounds

87 1,201 88 1,235 89 1,279 90 1,323 91 1,356 92 1,389 93 1,433 94 1,477

Code Pounds

95 1,521 96 1,565 97 1,609 98 1,653

99 1,709 100 1,764 101 1,819 102 1,874

Code Pounds

103 1,929 104 1,984 105 2,039 106 2,094 107 2,149 108 2,205 109 2,271 110 2,337

Page 20SKU 94564 For technical questions, please call 1-800-444-3353.

Page 21

Speed Rating- The speed rating denotes the speed at which a tire is designed to be driven for ex-

The weight of cargo should never exceed 789 kg or 1740 lb.

ORIGINAL TIRE

SIZE

LD TIRE INFLA

PRESSURE

WNER’S

MANUAL F

ADDI

NAL

INF

RMA

5.30-12

550 kPa,

80 P

TIRE AND L

ADING INF

RMA

The weight of cargo should never exceed 789 kg or 1740 lb.

ORIGINAL TIRE

SIZE

COLD TIRE

INFLATION

PRESSURE

SEE OWNER’S

MANUAL FOR

ADDITIONAL

INFORMATION.

5.30-12 550 kPa, 80 PSI

TIRE AND LOADING INFORMATION

•

tended periods of time. This does not indicate that the vehicle or rims can safely reach or maintain that speed.

These ratings are listed to the right. (The markings on the example tire diagram show M. The markings on your

tire may differ.) Note: You may not nd this information

on all tires because it is not required by law.

Tire Ply Composition and Materials Used- The num-

•

Tire Speed Rating Codes

Code MPH

F 50

G 56

J 62

K 68

L 75

M 81

Code MPH

N 87

N 87 P 94

P 94 Q 100

Q 100 R 106

R 106 S 112

S 112 T 118

T 118

Code MPH

U 124

U 124 H 130

H 130 V 149

V 149 Z 149

Z 149

W 168

Y 186

ber of plies indicates the number of layers of rubbercoated 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 Ination Pressure- This number is the greatest amount of air pressure that

•

should ever be put in the tire under normal driving conditions.

Tire Ination and Load Limit

Tire and Loading Information Placard

Tire and Loading Information Placard Location

The Tire and Loading Information Placard displays the cold tire ination 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.

Page 21SKU 94564 For technical questions, please call 1-800-444-3353.

Page 22

TIRE CARE

Checking Tire Pressure

Note: Underinated 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. Overinated 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 ination pressure also increases tires wear rate. Therefore, it is important to keep tires inated 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.

•

It is usually not possible to determine underinflation of radial tires by visual in-

• spection.

This vehicle has 80 PSI recommended cold tire ination 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 while being driven on. To check (or ll to) a tire’s cold ination, 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 ap-

pear higher than the actual cold tire ination.

Steps for Maintaining Proper Tire Pressure

Locate the recommended tire pressure on the vehicle’s tire information placard,

certication label, or in the owner’s manual. This trailer has 80 PSI recommended cold tire ination pressure.

Measure and record the tire pressure of all tires.

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 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.

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.

At a service station, add the missing pounds of air pressure to each tire that is

underinated.

Check all the tires to make sure they have the same air pressure.

Page 22SKU 94564 For technical questions, please call 1-800-444-3353.

Page 23

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 Specications 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.

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 properly 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 qualied mechanic should remove the tire from the rim, perform

the repair, and remount the tire.

Page 23SKU 94564 For technical questions, please call 1-800-444-3353.

Page 24

VEHICLE LOAD LIMIT

Steps for Determining Correct Load Limit

Locate the statement “The weight of cargo should never exceed XXX pounds” on

your vehicle’s placard.

That gure 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 capac-

ity.

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 signicantly.

Page 24SKU 94564 For technical questions, please call 1-800-444-3353.

Page 25

INSPECTION, MAINTENANCE, AND CLEANING

The Chart on the next page serves as a basic guideline for scheduling your trailer

maintenance. Maintenance may be different based on your local conditions, use

of trailer, and frequency of trailer use.

CAUTION! All maintenance, service, or repairs listed in this manual are only

to be attempted by a qualied service technician.

MAINTENANCE OF TRAILER

Coupler Before each use ensure proper t of coupler.

Check for lubrication quarterly and before/after storage of trailer.

Wheels and Hubs Check lug nuts before each use, and after rst 50 miles of tightening.

Add grease to bearings quarterly and after storage. Repack bearings annually and before storage.

Tires before/after Check the pressure (80 PSI, MAX) before each use and before storage.

Visually inspect tires before and after each use. Check tread life quarterly and before/after storage.

Electrical Check tail lights before each use and after storage.

Check brake lights before each use and after storage. Check electrical ground wiring before each use.

PLEASE READ THE FOLLOWING CAREFULLY

THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER 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 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 REPLACEMENT PARTS THERETO, OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO.

Page 25SKU 94564 For technical questions, please call 1-800-444-3353.

Page 26

PARTS LISTS & ASSEMBLY DIAGRAM

Trailer Parts List

Part Description Qty.

1FL Front Left Side Rail 1

1FR Front Right Side Rail 1

1RL Rear Left Side Rail 1

1RR Rear Right Side Rail 1

2A Cross Member 1

2B Cross Member 5

3L Left Connecting Rail 1

3R Right Connecting Rail 1

4 Angle Iron 2 5 T-Plate 1 6 Coupler Base 1 7 Coupler 1

Part Description Qty.

A M10 x 20 Bolt 38 B M10 x 25 Bolt 12 C M10 x 30 Bolt 2 D M12 x 40 Bolt 1 E M12 x 90 Bolt 2

F M14 x 30 Bolt 2 G M14 x 80 Bolt 4 H M10 x 30 Carriage Bolt 4

I M10 Nylon Nut 64

J M14 Nylon Nut 2 K M14 Hex Nut 4

Part Description Qty.

8 Safety Chain 1 9 L-Latch 2

12L Left Spring Hanger 1

12R Right Spring Hanger 1

14 Spring Plate 2 15 Spring 2 16 Axle 1 17 U-Bolt 4 18 Hub 2 19 Tire/Wheel Assy. 2 20 Bearing 2 21 Dust Cap 2

Hardware Parts List

Part Description Qty.

L M12 Lug Nut 10 M M20 Castle Nut 2 N 12 Flat Washer 1 O 20 Flat Washer 2

P 4mm Self Tapping Screw 5 Q 2mm R-Pin 1 R 3mm R-Pin 2 S 3mm Cotter Pin 4

T 4mm Cotter Pin 2 U M12 Nylon Nut 4 V M12 x 20 Bolt 1

Part Description Qty.

22 Fender 2 23 Fender Seat 2 24 Side Running Light 2 26 Tail Light Bracket 2 27 License Plate Bracket 1

28L Left Tail Light 1

28R Right Tail Light 1

29 Safety Pin 1 31 Grease Fitting 2 99 Grease Seal 2

28R

12L

28L

1RL

26 27

1RR

1FR

1FL

Note: Some parts are listed and shown for illustration purposes only, and are not available

individually as replacement parts.

Page 26SKU 94564 For technical questions, please call 1-800-444-3353.

Page 27

HARDWARE SPECIFICATIONS

LIMITED 90 DAY WARRANTY

Harbor Freight Tools Co. makes every effort to assure that its products meet high quality and durability standards, and warrants to the original purchaser that this product is free from defects in materials 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, 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 merchan-

dise. If our inspection veries 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 specic legal rights and you may also have other rights which vary from

state to state.

3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • (800) 444-3353

REV 07j

Page 27SKU 94564 For technical questions, please call 1-800-444-3353.