CADDY 640t User manual

STANDARD BODY ASSEMBLY INSTRUCTION - Caddy
Tools Required (Not
supplied
2 x 17mm Spanners
1 x 8mm Spanner
1 x 3mm Hexagon Key
1 x 6mm Drill Bit
1 x Torque Wrenc
FITTING
INSTRUCTIONS
A
B
C
D
E
F
F1
GH
K
L
1
1
1
1
4
1
1
1
2
2
2
C assis / Base Panel
Side Panel (rig t and)
Side Panel (left and)
Front Panel
Tail gate
Drawbar (Left and)
Drawbar (Rig t and)
Front C assis Reinforcing Angle
Drawbar stiffening Angles
Axle Complete
Suspensions Brackets (L & R and)
M
N
O
OS
P
Q
R
AF
AG
AH
AI
AJ
AK
1
2
2
2
4
2
2
2
1
1
1
4
2
Lig ting Baord
W eels / Tyres
Mudguard
Spray Accessories
Reflective Triangles
Front Corner posts
Rear Corner posts (L & R and)
Draw Bar Fixing Plates
Coupling
Drawbar Front Brace
Coupling Connection
Amber Reflectors
Front Clear Reflector / Cleats & M5 x 12mm
Hex Screws / nuts
AL
S
W
W1
X
Y
Z
Z1
AB
AC
AD
AE
AS
ST
2
2
40
1
41
14
42
4
6
18
1
8
1
1
Mudguard Brackets
Spring Fasteners & catc plates wit
screws
M10 x 20 Bolts
M10 x 40 Bolt /Nyloc Nut/ Flat
was er
M10 Nyloc Nuts
M5 x 25 Hex Screws
M5 x 12 Hex Screws
M6 x 10mm Cap Screws
Mud gaurds
M5 Nyloc Nuts
Coupling C ain & 'D' S ackle
Cable Clips
Skid
Ad esive Silver Tailgate Label
1. Wit t e aid of t e diagram identify all t e components in t e kit.
2. Lay t e trailer base upside down on a flat surface wit t e ribs facing upwards.
3. Loosely Assemble t e side panels ( B & C) to t e base using M5 x 12 Hex screws (Z) and loosely attac font panel (D) using Cap screws (Z).
4. Assemble font clear reflector and cleats (AK) using M5 x 12mm screws and nuts. Loosely assemble t e front conner posts (Q) and clear reflector (AK) as s own using screws (Z) T en raise
t e back of t e trailer and attac rear corner posts ® using M5 x 12 Hex ead (Z).
5. NOW TURN THE TRAILER UPSIDE DOWN to ensure t at assembly of your trailer your trailer is simple it is important t at you keep t e fixings in t e next few steps as losse as possible until
you are instructed to tig ten t em.
6. Loosely attac t e suspension mounting brackets (L) to t e sides of t e trailer as s own in diagram using t e M10 x 20 bolts (W) and Nyloc nuts (X).
7. Loosely attac t e Left and Rig t Hand drawbar (F) to t e front of t e suspension brackets (L) using drawbar fixing plates (AF) wit bolts M10 x 20 (W) and nuts (X). T e s orter sides of t e
drawbar fixing plates (AF) fixes to t e suspension brackets (L)
8. Loosely attac t e coupling connection (AI) and t e drawbar front brace (AH) and skid (AS) to t e front of t e drawbars (F&F1) t en attac t e coupling (AG) to t e coupling connection (AI)
using one bolt M10 x 20 (W), one M10 x 40 (W1) and nut (X). Attac t e coupling c ain (AD) to t e M10 x 40 bolt and secure using t e M10 Nyloc nut.
9. Fit t e front c assis reinforcing angle (G) under t e lip of t e front panel (D), fix t roug drawbars (F&F1) using bolts (W) and nuts (X)
10. Loosely attac t e drawbar stiffening brackets (H) to t e side drawbar (F & F1) and front panel (D) using bolts (W) and nuts (X).
11. Loosely attac t e suspension beams (K) to t e suspension bracket (L) using bolts (W) and nuts (X). Note t e arms to t e suspension unit s ould lay towards t e rear, as s own in diagram.(It is
advisable to to paint t e axle wit good quality rust protecting paint before fitting. T e axle supplied is coated wit primer only and may be prone to rust over a period of time.
12. Before tig tening all bolts and screws, ensure t at bot axles are running in alignment by laying a straig t edge along t e sides of t e ubs. Tig ten all t e t e bolts and screws.
13. Attac spray suppression (OS) to Mud guards (O) using bolts (Y) and nuts (AO). Attac t e mud guards to t e trailer using M5 x 25mm Hex screws (Y), repair was ers (AB) and nyloc nuts. (Do
not over tig ten). Now attac t e mud guard brackets (AL) to t e trailer.
14. Attac t e w eels to t e ubs using t e domed ead w eel nuts (WN). Ensure t at t e tyre valve faces outwards and t e domed end of t e w eel nuts must be against t e w eel. Tig ten t e
w eel nuts
15. Attac t e lig ting board as s own in t e diagram using M5 x 12mm Hex screws (Z) Feed t e cable t roug t e ole in t e rear lig ting recess and run t e front to t e trailer using t e cable clips
(AE) to secure along t e way
16. Turn t e trailer t e correct way up. Use caution not to damage t e rear end and lig ts.
17. Attac t e spring fasteners and catc plate (S) to t e rear panel and corner posts (R) using M5 x 12 Hex eads. Slide t e tailgate onto t e inges attac ed at t e base.
18. Fit t e triangles to inside and outside t e tailgate using screws (Y) and nuts (AC). Attac t e ad esive silver tailgate label (ST) outside t e tailgate. Attac t e self-ad esive reflectors to t e sides
NOTE: C eck all fixings ave been tig tened. Do t is again after first 100 miles and t en every 1000 miles t ereafter.
T e caddy trailer uses taper roller bearings w ic are pre-greased for assembly and require c ecking and re-greasing if necessary every 1000 miles. Grease nipples are provided on ub for t is purpose
Maximum carrying capacity 640 620kg, 700lbs. Maximum tyre pressure 30psi is recommended for general use.