tow dolly - harbor freight toolsimages.harborfreight.com/manuals/96000-96999/96083.pdf · hitching...

TOW DOLLY (2,800 LB. PAYLOAD CAPACITY)

Model 96083

AsseMBLY AnD OPerATIOn InsTruCTIOns

WArnInGIMPOrTAnT InFOrMATIOn

This Tow Dolly’s Hitch Coupler MUST be properly secured to the hitch ball of the towing vehicle. After assembly and attachment, pull up and down on the Hitch Coupler to make sure the hitch ball is fitting snugly in the Hitch Coupler. There must be no play between the hitch ball and Hitch Coupler. If there is play, tighten the Adjustment Nut until no play is present. If the Adjustment Nut is too tight, the Handle will not lock. Carefully read and follow the complete instructions in this manual BeFOre setup or use.

IF THe COuPLer Is nOT seCureD PrOPerLY, THe BALL COuLD COMe LOOse WHILe THe TOW DOLLY Is In MOTIOn, POssIBLY CAusInG PrOPerTY DAMAGe, serIOus PersOnAL InJurY, AnD/Or DeATH.

Distributed exclusively by Harbor Freight Tools®.

3491 Mission Oaks Blvd., Camarillo, CA 93011

Visit our website at: http://www.harborfreight.com

read this material before using this product. Failure to do so can result in serious injury. sAVe THIs MAnuAL.

Copyright© 2008 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. Diagrams within this manual may not be drawn proportionally. Due to continuing improvements, actual product may differ slightly from the product described herein. Tools required for assembly and service may not be included.

For technical questions or replacement parts, please call 1-800-444-3353.

SKU 96083 For technical questions, please call 1-800-444-3353.

COnTenTssPeCIFICATIOns ......................... 3

unPACKInG ................................. 3

GenerAL sAFeTY ruLes ......... 4WOrK AreA ..................................... 4equIPMenT use AnD CAre ......... 4serVICe ........................................... 5

sPeCIFIC PrODuCT WArnInGs AnD PreCAuTIOns .......................... 5

AsseMBLY InsTruCTIOns ....... 8

OPerATInG InsTruCTIOns ..... 9HITCHInG THe TOW DOLLY TO

THe TOW VeHICLe ....................... 9LOADInG A VeHICLe OnTO THe

TOW DOLLY ................................. 10unLOADInG A VeHICLe FrOM

THe TOW DOLLY ......................... 11unHITCHInG THe TOW DOLLY

FrOM THe TOW VeHICLe .......... 11OPerATIOnAL DO’s AnD DOn’Ts 12

TIre InFOrMATIOn .................. 13TIre TerMInOLOGY GLOssArY 13TIre MArKInGs ............................ 14TIre InFLATIOn AnD LOAD LIMIT 15

TIre CAre ................................. 15CHeCKInG TIre Pressure ........ 15sTePs FOr MAInTAInInG

PrOPer TIre Pressure ......... 16TIre sIze ........................................ 16TIre TreAD .................................... 16TIre rOTATIOn .............................. 16TIre BALAnCe AnD ALIGnMenT 16TIre rePAIr ................................... 16

VeHICLe LOAD LIMIT ............... 17sTePs FOr DeTerMInInG

COrreCT LOAD LIMIT ............... 17

InsPeCTIOn, MAInTenAnCe, AnD CLeAnInG ....................... 18

HuB BeArInG MAInTenAnCe .... 19

PArTs LIsT ................................ 20

AsseMBLY DIAGrAM ............... 21

LIMITeD 90 DAY WArrAnTY ... 22


sPeCIFICATIOnsMaximum Payload Capacity 2,800 PoundsGVWR (Gross Vehicle Weight Rating)GAWR (Gross Axle Weight Rating) 3,320 lb.

Maximum Towing Speed 55 MPH

Complete Tow Dolly Dimensions

10’ 6” Overall Length (Tongue to Load Ramp)99-1/2” Overall Width (Fender to Fender)6” Ground Clearance 74” Tongue Length (Coupler to Wheel Platform)83” Wide (Between Fenders)80” Outside Width (At Load Ramps)39” Width (Between Load Ramps)16” W X 31” L Load Ramps14” W X 20” Deep (Wheel Tubs)

Tongue Height 19” High (On Ball Center/Trailer Level)

Safety Chains1.26” Link (Welded) .31” Diameter 32.28” Long with “S” Hooks ASME Approved, Quantity 2

Tire Specifications DOT ApprovedST 185/80D131660 lb @ 65 PSI Cold

Tire Rim Size 5J X 13 (Five Hole/4-1/2” Center)

Trailer Lights Left and Right Tail Lights with Side MarkersClearance Lights, Amber

Tail Lamp Size #1157 Dual Filament (Stop and Tail)#194 (Clearance Lamp)

Ball Coupler Size and Rating 2”, 5000 lb Rating/Class III3” Tongue

Light Voltage Requirements 12 VDCShip Weight / Net Weight 535 lb. / 475 lb.

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

are included. If any parts are missing or broken, please call Harbor Freight Tools at the number shown on the cover of this manual as soon as possible.

save This ManualYou 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.

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GenerAL sAFeTY ruLesIMPOrTAnT 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 damage to the Tow Dolly, property damage, serIOus

PersOnAL InJurY AnD/Or DeATH.

sAVe THese InsTruCTIOns.

Work AreaKeep work area clean and dry. 1. Cluttered, damp, or wet work areas invite injuries.

Keep children away from work 2. area. At nO time should children play in, climb on or ride in this product.

Do not use this Tow Dolly if under 3. 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.

use eye protection. 4. Wear ANSI-approved safety impact eye goggles when assembling this product. ANSI-approved safety impact eye goggles are available from Harbor Freight Tools.

Dress safely. 5. 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.

Do not overreach. 6. Keep proper footing and balance at all times to prevent tripping, falling, back injury, etc.

Industrial applications must follow 7. OsHA requirements.

stay alert. 8. 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 CareCheck for damaged parts. 1. 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 2. accessories: When servicing, use only identical replacement parts. Only use accessories intended for use with this product. Approved accessories are available from Harbor Freight Tools.

Maintain this Tow Dolly with care. 3. Keep this product clean and dry for better and safer performance.

use the right equipment for the 4. 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.

serviceservice on this Tow Dolly must be 1. performed only by qualified repair personnel. Service or maintenance performed by unqualified personnel could result in a risk of injury.

When servicing this Tow Dolly, use 2. only genuine replacement parts. Follow instructions in the 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

DAnGer! TO PreVenT TrAFFIC 1. HAzArD AnD/Or DeATH, ATTACH sAFeTY CHAIn AnD PrOPerLY seCure HITCH BeFOre LOAD-InG Or TOWInG.

TO PreVenT serIOus InJurY 2. AnD/Or DeATH, DO nOT eXCeeD MAXIMuM PAYLOAD CAPACITY OF 2800 LB. Or 55 MPH MAXIMuM sPeeD.

Wear ANSI-approved safety goggles 3. and heavy-duty work gloves during assembly and use.

Do not let anyone ride on Tow 4. Dolly or in the towed vehicle.

Do not use Tow Dolly without 5. Fenders in place.

Properly install and secure the two 6. Loading ramps with 4 Bolts before attempting to use.

Pinch hazard; use care when 7. latching. Keep hands and fingers away during loading and movement.

use for intended purpose only; not 8. for aircraft purposes.

Inspect Tow Dolly before each use. 9. Do not use if damaged in any way.

Before attempting to tow any 10. vehicle with the Tow Dolly, read the manufacturers manual for warnings and instructions pertaining to towing that vehicle. Many vehicles (usually newer) may nOT be towed unless all wheels are OFF the ground. To do so can cause serious and/or permanent damage to a vehicles transmission.

Before each use, examine the Tow 11. Dolly for proper Tire air pressure (65 PsI cold), damaged tail lights, worn or damaged safety Chains, 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 Tow Dolly even if minor damage appears.

Do not allow adults, children, or 12. pets to ride in or play around, on, or under the Tow Dolly.

Before each use, attach the safety 13. Chains (52) of the Tow Dolly to the towing vehicle. Adjust the Safety Chains (52) to the same length on

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each side. Do not allow the Safety Chains to drag on the ground.

Properly and safely secure the 14. payload being transported to the Tow Dolly.

Make sure the towing vehicle and 15. the hitch on it is capable of towing the Tow Dolly and its payload. The towing capacity of the hitch is typically stamped on the hitch bar.

The Hitch Coupler (47) and the 16. vehicle’s ball hitch (not included) must be of equal mating size (2”) and rated equal to or greater than the weight of the Tow Dolly and its payload.

Do not exceed 55 miles per hour 17. when towing the Tow Dolly. Excess speed is a major cause of vehicle accidents. Poor road conditions, such as uneven, wet, or unstable surfaces, will create further hazards if driven on too fast. Reduce speed to a safe level when driving in poor driving situations.

The Tail Light Bulbs supplied with 18. this Tow Dolly 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.

Whenever possible, park the 19. Tow Dolly on a flat, level, paved, surface and chock both Tires to keep it from accidently moving.

This Tow Dolly should never be 20. backed if loaded with a vehicle. When there is NO vehicle on the Tow Dolly it may be backed using extreme care to keep from jack-knifing. Use extreme caution and back ONLY

if another person (outside the tow vehicle) is watching for people, traffic, and other obstacles. Do not back up if you are alone.

Maintain labels and nameplates 21. on the Tow Dolly. These carry important information. If unreadable or missing, contact Harbor Freight Tools for a replacement.

reporting safety defects: If you 22. believe your Tow Dolly 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.

Tow Dolly licensing notice: some 23. states may consider this Tow Dolly 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 Tow Dolly.


WArnInG! 24. 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.

sAVe THese InsTruCTIOns


AsseMBLY InsTruCTIOnsnote: For additional references to the

parts listed on the following pages, refer to the Assembly Diagram on page 21.

note: Only a qualified technician should 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.

The Axle Hubs (21) and Frame (19) 1. come pre-assembled.

The Tail Lights (24) are pre-wired and 2. attached to the rear of the Fenders (25 and 49). The Tail Light wire pigtails on the inside of Fenders (25 and 49) have to be properly attached to the wiring harness running from the Frame (19).

WArnInG! Use care to securely fasten the wiring that runs from the Tail Lights (24) to the Frame (19). It is on the inside of the Fenders (25 and 49) and needs to be kept away from the tires.

The Wheel Bearings (30) are 3. assembled to the Axle Hubs (21). NOTE: Before first use, remove the Dust Cap (31) on each wheel and check the Bearings (30) to insure they are properly greased. If needed, add grease and replace the Dust Caps (31). See “Hub Bearing Maintenance” on page 18 of this manual.

Place the Tow Dolly Axle across 4. blocks (not included) or use two jack stands (not included) to support the

Axle while the Fenders (25 and 49) and Wheels are being attached.

Slide each Wheel (22) onto an Axle 5. Hub (21). Secure the Wheels (22) with Lug Nuts (29), 5 per Wheel. Place a Dust Cap (31) on each Axle Hub (21) to keep dirt and debris out of the Wheel Bearings (30).

Slide Fenders onto top of Wheels and 6. use Lock Nuts (18) and Washers (17) to fasten Fenders onto side of Frame (19).

Lower the Tow Dolly to the ground so 7. that it is resting on both Wheels (22). Block both Wheels (22), in front and in back. Raise the Frame (19) and rest it either on blocks (not included), or on a jack stand (not included).

Insert the Tow bar (48) into the Collar 8. Bracket (36) and then into the Frame (19). Push the Tow Bar (48) as far as it will slide into the Frame (19).

Slide the Collar Bracket (36) onto 9. the Frame (19), line up the hole in the Frame (19) and the Tow Bar (48) and tighten the threaded lever on top of the Collar Bracket (36). Place the Safety Pin (34) through the two straps welded perpendicular at the point of Tow Bar’s entry into the Frame (19), securing it with an “R” Clip. Insert the M18 x 110mm Hex Bolt into the M18 Washer, then slide it through the horizontally drilled holes across the end of the Tow Bar (48) and the Frame (19). Attach Lock Nut and tighten.

Use Hex Bolt (41), Flat Washer (42) 10. and Lock Nut (43) to fasten the Side Braces (37) to the sides of the Tow Bar (48). Then use Hex Bolt (38),

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Flat Washer (39), and Lock Nut (40) to fasten the other ends of the Side bars to the front sides of the Frame (19).

Set the Top Panel (1) onto the Frame 11. (19), align the hole at its center with the one at the center of the Frame tube. Insert the M24 x 135 Hex Bolt (5) through Flat Washer M24 (6), and through the aligned holes. Attach the M24 Lock Nut (7) and tighten.

Attach a Winch (8) (not included) to 12. both the left and right Wheel Wells of the Top Panel (1) with a M12 X 30 Hex Bolt (2), a Flat Washer (3) and an M12 Lock Nut (4). The Winch (8) will be used to tighten the Harness (not included) over both front wheels of the vehicle you will be towing.

Fasten a Loading Ramp (20) securely 13. to the rear of both the left and right Wheel Wells with four M12 X 30 Hex Bolts (2), eight Flat Washers (3), and four M12 Lock Nuts (4).

OPerATInG InsTruCTIOns

HITCHInG THe TOW DOLLY TO THe TOW VeHICLe

Only use a 2” ball hitch (not included) 1. on the towing vehicle.

note: To reduce friction between the hitch ball (not included) and Hitch Coupler (47), apply a layer of heavy weight grease over the hitch ball (not includ-ed).

Temporarily remove the R-Clip and 2. Safety Pin (not included with Hitch Coupler 47). Then, pull up on the Trigger and lift up on the Handle.

With assistance, place the Hitch 3. Coupler (47) 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 fitting snugly in the Coupler. There should be no play between the hitch ball and Hitch Coupler (47). 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. Once the Hitch Coupler (47) is snug, replace the Safety Pin and the R-Clip (not included). WArnInG! If the Hitch Coupler is not secured properly, the ball could come loose while the Trailer is in motion, possibly causing property damage, serIOus PersOnAL InJurY AnD/Or DeATH.

Attach each of the safety chains 4. (52) with equal length to the towing vehicle’s rear bumper or frame. nOTe: If the safety chain (52) is too long, twisting it will take up slack.

Connect the Tail Light Wiring 5. Assembly to the towing vehicle’s 12 Volt DC system. nOTe: Consult the operator’s manual of the towing vehicle for proper connection instructions.

CAuTIOn! Care must be taken 6. when backing up the Tow Dolly.

When towing long distances, stop 7. and check the tightness of all connections, Side Running Lights, and Tail Lights at least every 100 miles.

Carry emergency flares, and a fire 8. extinguisher, if required for operation in your state.

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It is recommended to carry extra 9. bulbs and fuses if towing the Tow Dolly at night.

LOADInG A VeHICLe OnTO THe TOW DOLLY

Use a responsible adult as a helper.1.

Hitch the Tow Dolly to your tow 2. vehicle. (See instructions on page 9 of this manual.) Turn off the engine of your Tow Vehicle and exit. Block the Wheels (22) of the Tow Dolly (front and back of both tires).

To rest the Loading Ramps (20) 3. on the ground, remove the R-Clip (35) from the Safety Pin (34). Then loosen the threaded lever on top of the Collar Bracket (36), and while holding the Frame (19) with downward effort, slide the Collar Bracket (36) forward on the Tow Bar (48) allowing the Frame (19) to rise upward.

Using the helper, center the vehicle’s 4. tires in front of the Loading Ramps (20). Very slowly drive up the Loading Ramps (20) and into the Wheel Wells of the Top Panel (1). When the vehicle is fully loaded, the Frame (19) will drop onto the Tow Bar (48). WArnInG! Keep everyone clear of the lowering action of the Frame (19) onto the Tow Bar (48). This happens quickly and could cause severe injury to anyone standing too close. Do not have hands on the Frame as it is lowering. Place the loaded vehicle in neutral and exit.

Slide the Collar Bracket (36) forward 5. onto the Frame (19) and tighten the

Threaded Lever into the Frame (19). Push the Safety Pin (34) through the Frame (19) and Tow Bar (48) and lock it in place with the R-Clip (35).

6. Place the Wheel Bonnet Tie Down (SKU 97230, sold separately) over the wheel of the vehicle being moved, as shown above. Adjust the Hook end so that the bonnet is tight.

Attach the Hook End to a solid an-7. chor point. The safety clamp of the hook should be completely closed.

Secure the hook at the Ratchet End 8. to a solid connection point on the trailer that will not be damaged by tension.

Open and close the ratchet handle 9. to tighten strap over the tire. Avoid pinching fingers when working ratchet assembly. Lock handle down before use.

note: This nylon harness should be checked for security before you begin a trip and every 25 miles there af-ter. Also check frequently for fraying or any other damage and if found, replace the nylon harness. DO nOT rePAIr, ALWAYs rePLACe.

Remove the blocks from both sides of 10. the Tow Dolly Wheels.

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unLOADInG A VeHICLe FrOM THe TOW DOLLY

Use a responsible adult as a helper.1.

Block the wheels (front and back of 2. each tire) on the Tow Dolly. Turn off the engine of the tow vehicle.

Remove the nylon harness (not 3. included) from each of the front tires of the loaded vehicle.

nOTe: Do NOT leave the nylon harness (not included) laying on the Tow Dolly while you are loading or unloading a vehicle.

Enter the vehicle to be unloaded and 4. place your foot on the brake pedal and hold it there. Set the parking brake, take your foot off the brake pedal and start the engine. Place your foot back on the brake pedal.

Remove the R-Clip (35) and the 5. Safety Pin (34) from the Tow Bar (48) and Frame (19). Loosen the Threaded Lever on top of the Collar Bracket (36) and slide it forward on the Tow Bar (48) toward the tow vehicle. After this, stand away from the Tow Dolly, the tow vehicle, and the vehicle being removed from the Dolly. Stand where you can be seen clearly by the driver of the vehicle.

With your foot on the brake pedal 6. release the parking brake. Place the loaded vehicle in reverse and slowly ease the vehicle back off the tow dolly. Moving slowly will keep the Frame (19) from rising to quickly away from the Tow Bar (48) and it will keep the Loading Ramps (20) from hitting the ground hard enough to possibly damage them.

Once clear of the Tow Dolly, back 7. the vehicle a distance where you can safely move between the Tow Dolly and the vehicle that was just removed.

Using both hands and being sure 8. to keep your hands on the top of the Frame (19), carefully lower the Frame (19) back to the Tow Bar (48). Slide the Collar Bracket (36) over the Frame (19) and tighten the Threaded Lever on top of the Collar Bracket (36) till it is snug. Reinsert the Safety Pin (34) and the R-Clip (35).

unHITCHInG THe TOW DOLLY FrOM THe TOW VeHICLeDisconnect the Tail Light Wiring 1. Assembly to the towing vehicle’s 12 Volt DC system.

Unhook each side of the Safety 2. Chains (52) from the towing vehicle’s rear bumper or frame. Wrap the Safety Chains (52) and the excess wiring from the Tail Lights around the Tow Bar (48) to keep it secure and out of the way.

Temporarily remove the “R” Pin and 3. Safety Pin (not included) from the Hitch Coupler (47), Then, pull up on the Trigger and lift up on the Handle.

With assistance, lift the Hitch Coupler 4. (47) off the 2” ball hitch and back the Tow Dolly away from the tow vehicle about two feet. Set it carefully on the ground. Replace the R-Clip and the Safety Pin (not included) into the Hitch Coupler (47).

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OPerATIOnAL DO’s AnD DOn’Ts

DOn’T:1. This Tow Dolly was not designed for use in commercial applications. Commercial use will void warranty. DO NOT USE FOR AIRCRAFT PURPOSES.

DO:2. Make wide turns when towing a loaded Tow Dolly avoiding sharp, and U-turns. Turning too sharply can cause damage to the Tow Dolly and/or the tow vehicle.

DOn’T: 3. DO NOT ATTEMPT TO BACK A LOADED TOW DOLLY. This can overstress the Tow Dolly and possibly bend the Tow Bar (48) and/or the Frame (19).

DO:4. Before each use, check the Wheel (22), Lug Nuts (29) and the Top Panel (1) for tightness and security, and check tow dolly tire pressure (see pages 15 and 16).

DO:5. Check tire pressure on the tow vehicle before using. Check the manufacturer’s manual for the tow vehicle you are using.

DO: 6. Hitch the Tow Dolly to the tow vehicle before loading the vehicle to be towed.

DO:7. LOAD THE VEHICLE BEING TOWED FACE FORWARD. Immobilize the steering wheel by locking the ignition switch, or tying off the steering wheel to the seat frame or another suitable point.

DO: 8. Do not transport passengers, or heavy cargo inside the vehicle that is being towed.

DO: 9. If the vehicle being towed is a rear drive model, consult the vehicle manufacture to find out if the drive shaft should be removed prior to towing to prevent damage to the transmission. If the drive shaft does need removal, make sure the vehicle is on flat, level ground and all four wheels are blocked to prevent the vehicle from rolling, possibly causing injury and/or death.

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TIre InFOrMATIOn

Tire Terminology GlossaryAccessory weight means• - the combined weight of automatic transmission, power steer-ing, 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, 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 car-cass, 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 ad-ditional 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;a. Accessory weight;b. Vehicle capacity weight; andc. Production options weight.d.

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 kilo-grams 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 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.


Tire Markings

u.s. DOT tire identification

number

ratio of height to width (aspect ratio)

nominal width of tire in

millimeters

Trailer tire

Maximum load rating

Tire ply composition

and materials used

Maximum permissible

inflation pressure

Diagonal

rim diameter code

sT• - The “ST” stands for Special Trailer and indicates the tire is for trailers only.next number• - This three-digit number gives the width in millimeters of the tire from sidewall edge to sidewall edge. In general, the larger the number, the wider the tire.next number• - This two-digit number, known as the aspect ratio, gives the tire’s ratio of height to width. Numbers of 70 or lower indicate a short sidewall for improved steering response and better overall handling on dry pavement.D• - The “D” stands for diagonal tire fabric con-struction.next number• - This two-digit number is the wheel or rim diameter in inches. If you change your wheel size, you will have to purchase new tires to match the new wheel diameter.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 indi-cates the maximum load in kilograms and pounds that can be carried by the tire.Tire Ply Composition and Materials used• - The 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 manufac-turers 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 pres-sure that should ever be put in the tire under normal driving conditions.


Tire Inflation and Load Limit

Tire and Loading Information Placard

The weight of cargo should never exceed 1269 kg or 2800 lb.

TIre sIze COLD TIre Pressure see OWner’s MAnuAL FOr ADDITIOnAL

InFOrMATIOn.

FrOnT sT185/80D13 440 kPa, 65 PsI

reAr nOne nOne

sPAre nOne nOne

TIre AnD LOADInG InFOrMATIOn

09g

MO

DeL

960

83

Tire and Loading Information Placard Location

The Tire and Loading Information Placard displays the cold 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.

TIre CAre

Checking Tire Pressurenote: 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 pres-sure 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 gradu-• ally.

Tires can suddenly lose air if the • tire strikes a pothole, curb, or other object.It is usually not possible to deter-• mine underinflation of radial tires by visual inspection.

This vehicle has 65 PSI recom-mended 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 while being driven on. To check (or fill to) a tire’s cold infla-tion, 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.

reV 09g


steps for Maintaining Proper Tire Pressure

Locate the recommended tire pres-1. sure on the vehicle’s tire information placard, certification label, or in the owner’s manual. This trailer has 65 PSI recommended cold tire inflation pressure.

Measure and record the tire pressure 2. of all tires.

If the tire pressure is too high in any 3. 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 4. 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 5. pounds of air pressure to each tire that is underinflated.

Check all the tires to make sure they 6. have the same air pressure.

If the tires’ pressure was not mea-7. sured “cold”, then the pressure should be rechecked with the tires cold as soon as possible.

Tire sizeTo maintain safety, only purchase

new tires of the same size as the original tires. Look at the Tire and Loading Infor-mation 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 TreadThe tire tread provides traction that

prevents your vehicle from slipping, es-pecially 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 rotationEvery 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 AlignmentThe tires need to be balanced to pre-

vent 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 equip-ment that is not provided with this vehicle.

Tire repairTo 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 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 1. of cargo should never exceed XXX kilograms or XXX pounds” on your vehicle’s placard.

That figure equals the available 2. amount of cargo and luggage load capacity.

Determine the combined weight of 3. 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 4. and luggage load capacity, then the trailer be unsafe resulting in hazard-ous effects, such as: Trailer’s tires will not be able to maintain traction properly, and stopping distance will be increased significantly.


InsPeCTIOn, MAInTenAnCe, AnD CLeAnInGThe following Chart serves as a basic guideline for scheduling your trailer 1. maintenance. Maintenance may be different based on your local conditions, type of trailer, and frequency of trailer use.

CAuTIOn! 2. All maintenance, service, or repairs listed in this manual are only to be attempted by a qualified service technician.

MAInTenAnCe CHArT

Maintenance Type Before use

Before long

storage

After storage

After First 50 Miles

every 3 Months

every 6 Months Yearly

HitcH coupler

Ensure proper fit XCheck Lubrication X X XWHeels and Hubs

Check lug nut tightness X X X XGrease Bearings X XRepack Bearings X Xtires

Check Pressure (65 PSI) and Visual Inspection X X XCheck tread depth X X Xelectrical

Check Tail and Brake Light Operation X XCheck Electrical Ground Wiring X


HuB BeArInG MAInTenAnCeWArnInG! If the following 1. procedure is not followed, it may result in wheel locking and tire blowout, causing an automobile accident or road hazard. Whenever a Hub (21) on a new unit requires assembly (or a Hub is disassembled for maintenance), the following procedures MUST be followed:Using a suitable solvent, thoroughly a. clean the Bearings (30), Dust Cap (31), and the rest of the parts of 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 clean.Allow all parts to dry completely.b.

Clean your hands and the bearing c. packer (not included).Place fresh, clean bearing grease in d. the bearing packer.With the grease-filled bearing packer e. in one hand and the Bearing (30) 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.

As you finish assembling the Hub, be 9. careful not to get any dirt or debris on any part of the assembly.

Replace the Dust Cap (31) over each 10. Bearing (30)


PLeAse reAD THe FOLLOWInG CAreFuLLYTHE 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.

PArTs LIsTPart Description qty.

1 Top Panel 12 Hex Bolt M12 X 30 23 Flat Washer M12 64 Lock Nut M12 45 Hex Bolt M24 X 135 16 Flat Washer M24 27 Lock Nut M24 18 Winch (not included) 29 Light Bracket (Left) 110 Arresting Nut M6 411 Hex Bolt M6 X 15 412 Flat Washer M6 813 Lock Nut M6 414 Hex Bolt M18 X 110 115 Flat Washer 18 X 3 216 Lock Nut M18 117 Flat Washer M12 418 Lock Nut M12 419 Frame 120 Loading Ramps 221 Hub 222 Wheel 223 Light Bracket (Right) 124 Light 225 Fender (Right) 126 Hex Bolt M12 X28 827 Flat Washer M12 16

Part Description qty.28 Lock Nut M12 829 Lug Nut M12 X 1.25 1030 Bearing 231 Dust Cap 232 Flat Washer M24 X 3 233 Castle Nut M24 X 2 234 Safety Pin 135 R-Clip 136 Collar Bracket 137 Side Brace 238 Hex Bolt M12X 30 239 Flat Washer M12 440 Lock Nut M12 241 Hex Bolt M12 X 115 142 Flat Washer M12 243 Lock Nut M12 144 Hex Bolt M12 X 110 245 Flat Washer M12 446 Lock Nut M12 247 Hitch Coupler 148 Tow Bar 149 Fender (Left) 150 Cotter Pin 4 X 35 252 Safety Chain (not shown) 2

note: Some parts and hardware are listed and shown for illustration purposes only, and are not available individually as replacement parts or hardware.


AsseMBLY DIAGrAM

sAFeTY CHAIns (52) qTY 2 (nOT sHOWn)


LIMITeD 90 DAY WArrAnTYHarbor 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 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.

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

record Product’s serial number Here:

note: If product has no serial number, record month and year of purchase instead.

note: Some parts are listed and shown for illustration purposes only, and are not avail-able individually as replacement parts.

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