Harbor Freight Tools 600 lb. Capacity Boat Trailer Product manual
Contents
1. 8 nylon nut L Assemble two wooden plate base 16 to cross member 6 by using 3 8 x 1 bolt A 3 8 nylon nut L OM MRM RIO Me Re N Note The width between two wooden plate base 16 can be adjusted to fit the boat Siz STEP 2 DESCRIPTION 5 Axle Cotter Pin 2 Spring Plate K 4 U Bolt 2 Tire L 12 3 8 Nylon Nut 2 Fender M 4 9 16 Nylon Nut 2 Spring N 8 Lug Nut 2 Side Running Light O 2 Castle Nut 2 Hub R 2 3 4 Flat Washer 4 Bearing S 8 Spring Washer 2 Dust Cap T 2 Grease Fitting 4 9 16 x3 Bolt Z 4 3 8 x2 1 2 Bolt 4 Self Tapping Screw STEP 2 Turn the frame upside down Put the spring 20 on the spring hanger 12 with spring eyes forward secure with 9 16 x3 1 4 bolt H by going through spring hanger lock it with 9 16 nut M Then push a cotter pin P through the hole in the end of the bolt and spread it 3 Place Axle 5 on the top of spring 20 place spring plate 14 under spring using 3 8 U bolt K pass through axle spring and spring plate then lock it with spring washer S and 3 8 nylon nut L 4 Carefully slide hub 25 over spindle at each end of axle and push outer bearing and 3 4 flat washer R then castle nut tighten them smugly NOTE BACK OFF SLIGHTLY A LITTLE BIT SO THAT WHEEL CAN JUST MOVE FREELY Follow the Bearing Packing Instructions as explained on the last page of th2. connections and possible fraying or wearing of insulation Bulbs supplied with this trailer are for 12 volt system Bulbs used in tail light are Number 1157 Stop and Tail Bulb for clearance is Number 1895 TIRES Check tire for wear and proper inflation before each use and every 100 miles Tire pressure should be kept at 60 PSL Check and tighten lug nuts Torque to 85 90 FT LBS Retorque after first 50 miles OPERATION Know how to properly control your towing vehicle trailer combination on the highway under all conditions Remember the loaded weight of the trailer will increase your braking and stopping distances appreciably When towing a trailer over long distances stop and check tightness of all con nections lights and running gear every 100 miles Carry emergency flares and fire extinguisher if required for operation in your state It is desirable to carry extra bulbs and fuses if you are towing the trailer at night over any great distances INSPECTION MAINTENANCE AND CLEANING BEFORE EACH USE inspect the general condition of the Trailer Check for loose Bolts and Nuts misalignment or binding of moving parts cracked bent or broken parts excessively worn Safety Chain damaged Tail Lights Side Running Lights Wiring Harness loose Lug Nuts loose Hitch connnection and any other condition that may affect
3. its 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 Lbs 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 STICKER NOTICE SA IMPORTANT MES STICKER NOTICE to the towbar as shown And before using be sure each is followed TOWBAR Bearing Packing Instructions Important Read and adhere to the following instructions failure to read and obey all of the following instructions COMPLETELY will void the warranty and can result in damage to the trailer property damage or SERIOUS PERSONAL INJURY Whenever a hub is disassembled if a hub on a new unit requires assembly or a hub is disassembled for maintenance the following
4. 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 in cluded is also thoroughly clean Place fresh clean bearing grease in the packer With the grease filled bearing packer in one hand and the bearing in the other press the bearing into the grease forcing the grease inside the slots in the bearing con tinue doing this until every slot in the bearing is completely full of grease 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 12
5. OWNER S INSTRUCTIONS DIY BOAT TRAILER gt WARNING IMPORTANT INFORMATION This trailers Hitch Coupler MUST be properly secured to the hitch ball of the towing vehicle After assembly and attachment pull up and down on the Hitch Coupler to make sure the hitch ball is fitting snugly in the Hitch Coupler There must be no play between the hitch ball and Hitch Coupler If there is play tighten the Adjustment Nut until no play is present If the Adjustment Nut is too tight the Handle will not lock Carefully read and follow the complete instructions in this manual BEFORE setup or use If the Coupler is not secured properly the ball could come loose while the trailer is in motion possibly causing property damage SERIOUS PERSONAL INJURY or DEATH SPECIFICATION Item No 5002 Overall length 154 Overall width 52 1 2 Max load capacity 600 LBS Coupler capacity Class I 2000 LBS max gross load fit for 1 7 8 ball REV 10 04 Se kaga a a NAN NT ah aa an Ka a a aaa Na aa aa anaa I a a EENEN E TETA SE 3 8 x 1 1 2 Read the instructions carefully and follow them step by step for easy assembly You ll find a complete parts list on the previous page Average assembly time is approximately 3 hrs You ll need the following tools to assemble your Boat Trailer TOOLS NEEDED 9 16 box end wrench Pliers 9 16 open end wrench Channel lock pliers 3 4 socket or lug wrench Screwd
6. en when backing up the Trailer only back up the trailer on a Make sure vehicle is capable of towing the load straight path If the Trailer is allowed to turn f i off the straight path while backing up the Trailer Excess speed is the second most important could jackknife causing severe damage to the cause of car trailer accidents Recommended trailer and to the towing vehicle maximum speed for all passenger cars towing trailers is 45 M P H HITCH BALL COUPLER Check that the hitch on the towing vehicle is capable of towing the trailer The towing capability of the hitch is normally stamped on hitch drawbar Make sure the coupler and the ball are mating sizes and are rated equal to or greater than the load Never attach anything other than the proper size coupler to the ball for towing SAFETY CHAINS Be sure to use safety chains Check that safety chains are attached to towing vehicle with the same length for each side Do not allow chains to drag on ground LOADING Never overload trailer Maximum load is 600 Pounds It is important that the tongue be pressing down on the hitch but not exceeding a downward force of 60 Pounds It is against the law to carry passengers in the back of any trailer LIGHTING Check lighting before each use and every 100 miles to be sure stop tail and turn signals are working properly Replace any broken lenses reflectors or bulbs Check wires for good
7. ere should be no play between the ball and coupler If there is play tighten the adjustment nut until no play is present If the nut is too tight the handle will not lock NOTE To reduce friction between the ball hitch and coupler apply a layer of multi purpose lithium grease over ball hitch Wipe off excess grease when not in use to avoid staining clothes TRIGGER ADJUSTMENT NUT HITCH BALL 1 7 8 HITCH TRAILER LICENSING NOTICE Some states may consider that this trailer kit is a specially constructied or homemade vehicle for registration licensing and or titling purposes The M C O Manufacturer s Certificate of Origin supplied with your trailer should be filled out and signed by the dealer transferring ownership to you When licensing your trailer you will need the signed M C O a purchase invoice cash re gister receipt or bill of sale showing the purchase and retail sales tax or use tax collection by the retailer Take these to your local Department of Motor Vehicle and upon payment of the appro priate State fees you will be issued a title registration and license plate if required Some states will require inspection of the assembled and finished trailer kit before issuing a titleregistration license If you require additional information or guidance on licensing or titling please consult your State Department of Motor Vehicles SAFE USE AND OPERATION RULES CAUTION TOWING VEHICLE Care must be tak
8. is manual 5 Put tire 18 on hub set 25 then lock with 4 lug nuts N tighten with socket or lug wrench to 90 LBS VERY TIGHT Note Air valve should be on outside of rim Be sure that axle is perpendicular to side rail and springs are parallel to side rail 6 Push a cotter pin J through the hole at the end of the spindle spread cotter pin 1 4 fill the dust cap 27 with automative grease then press it onto the hub then fix grease fitting T to the end of dust cap 27 7 Open the lens of side running light 21 with self tapping screw I and screws run wire lead through the center hole to firm wire tightly on side rail 8 Bolt fender 19 to side rail by using 3 8 x 2 1 2 bolt Z nylon nut D N STEP 3 1 Turn over the trailer assembly make two 0 tires touch ground 2 Bolt coupler 24 Coupler Base 28 to Orientation Bar Towbar 1 by using 3 8 x 3 Bolt Roller Base Small Nylon Nut CL through the side of Roller Small coupler 24 Brace Attach safety chain 23 to coupler with Wooden Plate 3 8 x 1 1 2 bolt B go through the top Tail Light front hole of coupler and center link of License Plate Bracket the chain lock with 3 8 flat washer Safety Chain Q and 3 8 nut L Note Make sure Coupler safety chain is the same length each side Coupler Base Using 3 8 x 4 bolt F go through 3 8 x 1 1 2 Bolt top rear hole of coupler and towbar to 3 8 x 3 Bol
9. river NOTE 1 In assembling trailer parts they are called out by standing at rear of trailer and looking toward tongue 2 The nuts and bolts shouldn t be completely tightened until the entire trailer is assembled All the nuts and bolts should be checked periodically for tightness and you should retighten the lug bolts on the wheels after the first 20 miles of use STEP l Lay out two side rail 2 towbar 1 Connecting rod 4 cross member 6 roller base 8 and connecting plate 11 Towbar as shown Side Rail Assemble 1 2 4 6 11 using 3 8 x4 bolt Connecting Rod 3 8 nylon nut F L Cross Member The same time put one roller base large Roller Base Large 8 on center of connecting rod 4 using Roller Large 3 8 x4 bolt A through the center hole of Connecting Plate roller base 8 connecting rod 4 and tow Wooden Plate Base bar 1 then lock with 3 8 nylon nut L 3 8 x 1 Bolt Use 3 8 x1 bolt A through both side 3 8 x 4 Bolt hole of roller base 8 connecting rod 4 3 8 x 6 Bolt then lock with 3 8 nylon nut L 3 8 Nylon Nut Put another roller base 8 on center of cross member 6 using 3 8 x1 bolt A through both side hole of roller base 8 and cross member 6 then lock with 3 8 nylon nut L Do not tighten nylon nuts until all bolts are positioned in place Put roller 9 on roller base 8 then assemble it by using 3 8 x 64 bolt G 3
10. rt their 5 wire system to wire vehicle connector L H Stop amp Turn Yellow Tail License lilum Brown R H Stop amp Turn Green Running Lite Ground White Ground White eee Wire Harness l S Steel Wire I i Connector Yellow f Green Connector l y Wire From Light Brown Wire Brown From Light Attach white ground wire at plug end of wiring harness to the small hole in right tongue with safety tapping screw Leave about 18 of wire beyond the coupler and lay out wire on the inside of right tongue to the side rail joint as shown then from this joint split the yellow brown wire and green brown wire Make yellow brown go through cross member to left running light make green brown wire go to the right running light Connect the wire lead from the running lights to the brown wire on each side with the wire connector Use pliers to squeeze the connector closed Cut yellow brown and green brown wires to appropriate lengths and strip ends of wires Make taillight connections as per color code Left side Right side Yellow Red wire Green Red wire Brown Two black wires Brown T wo black wires SPECIAL NOTICE FOR COUPLER Only use a 1 7 8 ball hitch on your towing vehicle Pull trigger and lift handle Place coupler ove trailer hitch ball and push down on handle until trigger locks in slot Pull up and down on the coupler to see if the ball is fitting snugly in the coupler Th
11. t lock with 3 8 nylon nut L 3 8 x 34 Bolt Bolt roller base small 7 to orientation 3 8 Carriage Bolt bar 3 with carriage bolt E and nylon 3 8 x 4 Bolt nut L then assemble roller 10 to roller 3 8 Nylon Nut base 7 with 3 8 x 4 bolt 3 8 nylon 3 8 Flat Washer nut F L Note The position of roller base can be adjusted to fit the boat size DO at W O ka ee ND NO ND ed pat on N po Install orientation bar 3 to towbar 1 with braces 13 on both side of towbar using 3 8 x 3 bolt brace Nylon nut D 13 L Install wooden plate 15 to wooden plate base 16 by using 3 8 x 3 bolt nylon nut C L as shown Install license plate bracket 22 and left tail light 17 with clear lens for light with nuts then install right tail light 17 STEP 4 TRAILER LIGHT KIT WIRING DIAGRAM AND INSTRUCTION NOTE Insert a steel wire through A and B hole to pull wire harness out Check alignment of all parts and install the 4 wire vehicle connector in the trunk area of your car Locate the connector plug near the hitch ball and lay out wires Refer NOTE to lay out wires Connect the white wire to the frame or body of the car connect the brown wire to the tail light by stripping wrapping and taping connector similarly connect the yellow wire to the left signal and stop light wire and the green wire to the right signal and stop light wire Some foreign vehicles may require an adaptor to conve
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