Malone MPG460G 2010 User Manual

MPG460G

TM

Malone MicroSport Trailer

01-2010

Model MPG460G Assembly Instructions

Take a few moments now and read through these instructions.

Familiarize yourself with the step by step assembly process before you

begin turning wrenches. Un-pack and sort the components into groups as

shown in the following photos. Then you will assemble each group in order.

Lets get started !!

Required Tools:

• 3/4” wrenches (2) • 9/16” wrenches (2) a 9/16” deep socket is very handy.

• Large at blade screw driver • 7/16” wrench (1)

• Razor knife • Pliers

• Wire stripping tool • Electrical connector crimping tool

• Lug wrench • Small hammer

Visit us at

maloneautoracks.com

for more ne products and accessories.

800-295-0042 ext 206

1

[e-mail]

MPG460G

Group 1:
Frame
Components

01-2010

Bag 11462

Group 2:
Axle / Spring
Components

Bag 11467

800-295-0042 ext 206

2

[e-mail]

MPG460G

01-2010

Group 3: Lighting Components

Group 4:

Bag 11464

Fender Components

Bag 11468

Group 5: Coupler Components

800-295-0042 ext 206

Bag 11494

3

[e-mail]

MPG460G

Group 6:
Load Bar
Components

01-2010

Bag 11497

800-295-0042 ext 206

4

[e-mail]

MPG460G

FRAME ASSEMBLY (Group 1)

1. We assemble the frame on its back to make it easier to install the springs
and axle. Once the springs and axle assembly is installed we will ip the trailer
over to complete the assembly. So rst, layout the frame components upside
down as shown. The spring bracket mounting holes should be facing up. All
the decals should be upside down.

01-2010

2. Attach the spring
hanger brackets
to the frame. The
U shaped shackle
bolt brackets mount
to the front and the
C shaped “slipper”
brackets mount to the
rear as shown. Use
3/8” x 1” bolts and
nuts. Assemble with the nuts on the inside of the frame rails. Fully tighten all 8 bolts now.

3. Identify the hitch end of the
tongue by the 3 holes on the left
side. Insert the small wire pro­tection grommet into the lower
hole where shown, then push it
all the way in till it snaps in place.

800-295-0042 ext 206

5

[e-mail]

MPG460G

4. Pass the wiring harness into the grommet and out the front end of
the tongue as shown. Stretch out the white wire and leave an equal
length of the green/
brown/yellow wire
outside the grom­met as shown. This
length of wires will
be the connector to
your tow vehicle.

5. Roll this wire so it
doesn’t get accidentally
pulled inside the tongue.

01-2010

6. Now its time to pass the wire ends thru the
tongue. Make sure the wires are tangle free, then
attach a weight to the end of the wires. A large
socket works great as shown or you could tape
a big bolt to the wires. Tip the tongue up and let

gravity work for you. Feed the wire and let
the weight slide through the tongue pulling
the wires with it.

800-295-0042 ext 206

6

[e-mail]

MPG460G

7. Installing the rear tongue support
bracket. First we lay the tongue back in
its place making sure its upside down.
Push the large wire protection grommet
into the rear tongue support bracket hole,
then pass the wires through the grommet.
Install the 4-1/2” long x 1/2” bolt up from
the bottom through the tongue support and tongue. Be careful not to pinch
the wires. Add a washer and nut. Hand tighten only.

01-2010

8. Bolt the tongue support to the frame
rails using 3/8” x 1” carriage head bolts.
Note the square heads go on the out­side with the square holes in the frame.
Assemble with washers and nuts on the
inside. Hand tighten only.

800-295-0042 ext 206

7

[e-mail]

MPG460G

9. Clamp the frame rails around the
tongue as shown using two 1/2” x
3-1/4” bolts. Use a washer on both
sides. Hand tighten only.

10. Lay the two frame cross mem­bers in between the frame rails. The
two holes in the middle should face
DOWN as shown. Bolt the frame
rails to the cross members using 3/8”
x 1” carriage bolts and nuts, (no washers). The square carriage
heads go to the outside with the square holes in the frame rails.
Hand tighten only.

01-2010

800-295-0042 ext 206

8

[e-mail]

MPG460G

11. TIME TO TIGHTEN

FRAME BOLTS: Its important

to follow this tightening sequence in
order to insure the trailer will be straight
after everything is tight.

A) Tighten the 8 nuts holding the ends
of the two cross members.

B) Tighten the rear tongue support bracket. Check that
you installed washers under the 4 nuts as shown. Evenly
tighten the 4 nuts.

01-2010

C) Tighten the two tongue
bolts snug to the frame rails.

DON”T overtighten, you will
just crush the tongue.

800-295-0042 ext 206

9

[e-mail]

MPG460G

D) Tighten the big bolt thru the
rear of the tongue and tongue
support.
Not too tight, don’t crush the
tongue.

01-2010

Your frame assembly is now complete and should look like this.

800-295-0042 ext 206

10

[e-mail]

MPG460G

SPRING AND AXLE ASSEMBLY
(Group 2)

1. Set the envelope containing the manufacturer’s
certicate of origin (MCO) and VIN labels aside in a
safe place.

01-2010

3. Lay the springs on top of the axle
with the centering studs in the holes
in the axle. Then assemble the
U-bolts, tie plates and nuts as shown.

Make sure both springs are
turned with the ends facing the
same way!!!

2. Spin the axle to nd the side with the spring
centering holes. These holes mate with the
spring center stud as shown to the left.

800-295-0042 ext 206

11

[e-mail]

MPG460G

4. Run each nut down UNTIL

IT TOUCHES THE PLATE
ONLY! DON’T TIGHTEN !!

You will need to wiggle the
springs to t them into the
spring brackets in the next
step.

01-2010

5. Lift the axle/spring assembly to the trailer frame and slide the slipper spring
ends into the slipper spring brackets as shown

800-295-0042 ext 206

12

[e-mail]

MPG460G

8. Wiggle the spring eyes into the front hanger
brackets and bolt using 1/2” x 3” bolts and self
locking nuts. Tighten the shackle bolts ONLY
until they grip the sides of the brackets. This is a
hinge, the spring needs to move freely.

9. Now that the axle assembly is
attached to the frame, tighten the
axle U-bolts evenly until there is a
slight bend in the tie plates.

10. Slip the hub caps thru the
wheels from the back then mount
the wheels onto the hubs and
hand tighten the lug nuts.

01-2010

11. From behind the trailer, lift the
rear cross member and roll the
trailer over onto the tires.

ALWAYS BEND FROM YOUR
KNEES WHEN LIFTING. IF THE
TRAILER IS TOO HEAVY FOR
YOU TO FLIP SAFELY FIND
FRIENDS TO
ASSIST YOU.

12. Tighten
the lug rmly
to 75 to 85
foot pounds
of torque.

800-295-0042 ext 206

13

[e-mail]

MPG460G

LIGHT ASSEMBLY (Group 3)

REFERENCE:
Trailer Wiring Color Code

•Brown = running lights

•Yellow = left turn / left brake

•Green = right turn / right brake

•White = ground

01-2010

1. Attach the tail lamp brackets to
the frame as shown using 3/8” x 1”
carriage head bolts and nuts. No
washers are needed.

2. Sandwich the license plate mounting
bracket between the left side lamp and
the left side tail lamp bracket. Attach
the tail light using the nuts provided with
the lamp kit. Then mount the right side
lamp.

3. Use the 3 holes just above
the spring bracket to mount the
amber side lamps. Put the stud
through the forward hole and the
wire through the rear hole. Tuck
the wire so the lamp sits ush on
the frame. The middle hole is
unused.

800-295-0042 ext 206

14

[e-mail]

MPG460G

4. Check the coil of wiring harness outside the tongue grommet.

5. Route the GREEN/BROWN
wire along the RIGHT side of
the frame.
Route the YELLOW/BROWN
wire along the LEFT as shown.

6. Use the clips provided to secure the wire to
the inside of the frame channel as shown

01-2010

7. Route the wires thru the mid cross member as shown then secure the harness in place using
the frame clips provided. Use your knife to CAREFULLY divide 1/2” of the green/brown wire and

the yellow brown wire
just below the side
lamp as shown.

8. Then grasp either side of the cut with your nger­nails and pull to separate 3” of wire as shown.

800-295-0042 ext 206

15

[e-mail]

MPG460G

9. Press the brown wire into the quick connec­tor as shown. Then insert the wire from the side
marker light fully into the 2nd opening. Use
pliers to squeeze the conductor blade down
and thru the insulation. The blade cuts thru the
insulation and connects the wires inside. Flip
the cover to lock the connector. Repeat on the
other side again using the brown wire.

10. Route the wires out to the tail
lights via the slotted hole under
the lamp brackets. Determine how
much excess wire to cut off. Be
sure and leave yourself a few inch­es of extra wire. You can always
cut away more later if need be.

01-2010

11. Strip 1/2” of insulation off the ends of
all 4 tail light wires. Twist the exposed
copper strands to stiffen them.

12. There are holes in the back side of
each lamp marked by wire color. Identify
which hole is for which color
wire. Then carefully push
the twisted wire straight into
the corresponding hole.
You will feel the wire slide
under the wire gripper inside
the lamp as you push the
wire into it. Once the wire
is pushed in it will not come
back out. Tug gently to
check for a good connection.
Repeat on the other side.

800-295-0042 ext 206

16

[e-mail]

MPG460G

FENDER ASSEMBLY (Group 4)

01-2010

1. Connect all 4 fender brackets to the fenders using 3/8” x 3/4” slot head
screws and nuts. Assemble with the nuts to the inside of the fenders as
shown. No washers here.
Fully tighten all 8 screws
and nuts.

Note that fenders are
symmetrical and will t
on either side of the trailer.

800-295-0042 ext 206

17

[e-mail]

MPG460G

Note that when bolting the mounting brackets to the frame you will install a
washer on both sides, under the head of each bolt and under each nut.

4. Using 3/8” x 1” bolts, washers on both
sides, and nuts, attach the fender brack­ets to the slotted holes in the frame as
shown. NOTE you will use the center
hole in the bracket and the outside two
slotted holes in the frame.

01-2010

5. Tighten bolts fully and repeat for other side.

800-295-0042 ext 206

18

[e-mail]

MPG460G

COUPLER
ASSEMBLY
(Group 5)

01-2010

1. Installing the ground wire con­nector. Strip 3/8” of insulation off the
white ground wire and crimp on the
ring connector as shown.

2. Assemble the tongue skid and safety chain
assembly with a 3/8” x 1-1/2” bolt as shown.
Use washers above and below the chain ends.

800-295-0042 ext 206

19

[e-mail]

MPG460G

3. Place the skid and chain
assembly under the tongue
and insert the bolt up through
the skid bolt hole on the bot­tom of the tongue as shown.

4. Slip the ring terminal over
the bolt and install the nylon
lock nut hand tight.

5. Check that the rear end
of the skid is still in its hole
in the bottom of the tongue.
Tighten the bolt while holding
the nut stationary. This way the ring terminal remains straight.

01-2010

800-295-0042 ext 206

20

6. Install the coupler on
the tongue and fully tighten
as shown. Tighten until
the coupler is tight onto
the tongue. Don’t crush
the coupler and tongue by
tightening excessively.

[e-mail]

MPG460G

LOAD BAR ASSEMBLY (Group 6)

01-2010

bag 11497

1. Attach a load bar support tube onto the

rear cross member. Cross the U-Bolts.
Center the support tube and brackets on the
trailer and tighten.

2. Attach the second support tube 48 inches forward.
Install these U-bolts parallel, not crossed. Measure
48” on both sides of the trailer to be sure the load bar
is on straight, then tighten the U-bolts.

800-295-0042 ext 206

21

[e-mail]

MPG460G

3. Use your hammer and carefully pound the end plugs into
the ends of the support
tubes. Install the caps onto
the ends of the U-bolts.

4. Install the load bar brackets onto the ends of each

tube and turn the bracket so the 2 hole ange is level.
Snug the mounting bolt.

5. Slip 2 carriage bolts into
the end of each load bar.

01-2010

6. Flip the load bar over and insert the
carriage bolts into the load bar brackets. Add
nuts, center the bar and tighten.

7. Install the end caps on the load bars

8. Go back now and re-check that all nuts and bolts
on the entire trailer are securely tightened.

800-295-0042 ext 206

22

[e-mail]

MPG460G

01-2010

Apply the supplied VIN Decal and TIRE AND LOADING Decal as shown below,

onto the left side of the towing tongue near the coupler on either side of the

CAUTION Decal. Be sure to clean the frame well before applying the decals.

Your MicroSport Trailer is now complete and ready to register and title !

Contact your local DMV ofce for specic procedures in your State.

800-295-0042 ext 206

Visit us at

maloneautoracks.com

for more ne products and accessories.

23

[e-mail]