HAUL MASTER 44649 Installation manual

LOAD RAMPS
1000 LB. CAPACITY (AS PAIR)
Model 44649
SET UP AND OPERATING INSTRUCTIONS
Roll dirt bikes, ATV’s and more into your pick-up!
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©2000 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.
Manual Revised 09l

Page 2 For technical questions, please call 1-800-444-3353. SKU 44649
SAVE THIS MANUAL
Keep this manual for the safety
warnings and precautions, assembly,
operating, inspection, maintenance and
cleaning procedures. Write the product’s
serial number in the back of the manual
near the assembly diagram (or month
and year of purchase if product has no
number). Keep this manual and the
receipt in a safe and dry place for future
reference.
IMPORTANT SAFETY
INFORMATION
In this manual, on the labeling,
and all other information
provided with this product:
This is the safety alert
symbol. It is used to alert
you to potential personal
injury hazards. Obey all
safety messages that
follow this symbol to avoid
possible injury or death.
DANGER indicates
a hazardous
situation which, if not
avoided, will result in death or
serious injury.
WARNING
indicates a
hazardous situation which, if
not avoided, could result in
death or serious injury.
CAUTION, used
with the safety
alert symbol, indicates a
hazardous situation which, if
not avoided, could result in
minor or moderate injury.
NOTICE is used to
address practices
not related to personal injury.
CAUTION, without
the safety alert
symbol, is used to address
practices not related to
personal injury.
WARNING! Read all instructions
Failure to follow all instructions
listed below may result in serious
injury and/or DEATH.
SAVE THESE INSTRUCTIONS
Load vehicle slowly. Do not ride a1. vehicle up or down the load ramp.
All persons not involved in the2. loading process must stand
clear of the loading ramps. Keep
children away. Children must not be
allowed in the work area.
Do not exceed the 1000 lb. per3. pair, or 500 lb. per Ramp maximum
weight capacity. Doing so can result
in personal injury and/or damage
to the ramp. Be aware of dynamic
loading! If the load drops or bounces
it may briey create excess load
causing product failure.
Check maximum tailgate weight4. capacity. Do not exceed tailgate
capacity if less than 1,000 lb.
Avoid working alone5. . If an accident
happens, an assistant can bring help.
Keep work area clean and well6. lit. Cluttered and dark areas invite
injuries.

Page 3For technical questions, please call 1-800-444-3353.SKU 44649
Store idle equipment7. . When not in
use, store ramps in a dry location to
inhibit rust.
Dress properly8. . Do not wear
loose clothing or jewelry. Protective
clothes and nonskid footwear are
recommended when working. Wear
restrictive hair covering to contain
long hair.
Wear ANSI-approved impact9. safety goggles, a safety helmet,
and heavy-duty work gloves when
loading, unloading or handling
ramps.
Keep proper footing and balance10. when loading or unloading.
Use as intended only.11. Do not use
as a ladder. Do not modify this
product.
Stay alert12. . Watch what you are
doing, use common sense. Do not
use any ramp when you are tired.
Check for damaged parts13. . Before
using any ramp, any part that
appears damaged should be carefully
checked to determine that it will
perform its intended function. Check
for any broken parts or mounting
xtures and any other condition that
may affect proper operation. Any part
that is damaged should be properly
repaired or replaced by a qualied
technician.
Replacement parts and14. accessories. When servicing, use
only identical replacement parts.
Use of any other parts will void the
warranty. Only use accessories
intended for use with this ramp.
Do not use ramp if under the15.
inuence of alcohol or drugs.
Read warning labels on prescriptions
to determine if your judgment or
reexes are impaired while taking
drugs. If there is any doubt, do not
use the ramp.
Use Ramps on a solid, level, at, dry 16.
surface. The ange must face down
and the Tongue (2) edge must fully
contact the tailgate.
Before each use, clean dirt, oil, and17. any debris off ramps.
The warnings, cautions, and18. instructions discussed in this
instruction manual cannot cover all
possible conditions and situations
that may occur. It must be understood
by the operator that common sense
and caution are factors which cannot
be built into this product, but must be
supplied by the operator.
REV 03d, 06f, 09e

Page 4 For technical questions, please call 1-800-444-3353. SKU 44649
SPECIFICATIONS
Capacity 1,000 lb. combined,
500 lb. individually
(Static Conditions)*
Max. Tailgate Height 36”
Dimensions 72” L x 9” W x 2” H
* Bouncing or dropping onto ramps
increases the load and reduces rated
capacity substantially.
UNPACKING
When unpacking, make sure that the
item is intact and undamaged. If any parts
are missing or broken, please call Harbor
Freight Tools at 1-800-444-3353 as soon
as possible.

Page 5For technical questions, please call 1-800-444-3353.SKU 44649
ASSEMBLY
Read the ENTIRE IMPORTANT
SAFETY INFORMATION
section at the beginning of this
manual including all text under
subheadings therein before set
up or use of this product.
Flange
TOP
END VIEW
WARNING! In the following assembly
process, the ange pictured above
must face down with the Tongue
(2) edge fully contacting the
tailgate. It is designed to keep the
Ramps from moving once the weight
of the load is riding on the ramp.
Note: For additional information regarding
the parts listed in the following pages,
refer to the Assembly Diagram near
the end of this manual.
Line up the four holes on the Tongue1. (2) with the four holes on the Ramp
(1). Insert four Bolts (3) from the
top (as pictured on the Assembly
Drawing) and secure with Flat
Washers (6), Lock Washers (4), and
Nuts (5).
Attach a 5/16” grade 30 coil chain2. (not provided) under the ramp to one
of the Bolts (3) used in the last step.
Repeat with other ramp.3.
REV 03d, 07k
Tongue
Edge Correct Wrong

Page 6 For technical questions, please call 1-800-444-3353. SKU 44649
OPERATION
Read the ENTIRE IMPORTANT
SAFETY INFORMATION
section at the beginning of this
manual including all text under
subheadings therein before set
up or use of this product.
WARNING! The vehicle that is1. being loaded into must be turned
off and in gear or park, with the
emergency brake engaged and the
wheels blocked.
WARNING! Each individual Ramp2. must have a safety chain (not
included) correctly installed and
connected (see #6 below). Make
sure each Ramp is clean and dry
before loading.
WARNING! Wear a safety helmet,3. ANSI-approved safety goggles,
heavy-duty work gloves, and steel-
toed work boots at all times during
loading and unloading.
The tailgate the ramps will sit on and4. both of the ramps must be dry and
clean. Check for and tighten any
loose hardware
Sit the tongue (angled lip) of the5. Ramp on the tailgate. The Tongue
Edge must face down (see Assembly)
fully contacting the tailgate of the
truck. Extend the Safety Chain (not
included) on each Ramp up into the
inside of the truck bed; attach each
Safety Chain to a secure attachment
point on the truck chassis.
WARNING! CONNECT SAFETY CHAINS
TO SECURE ATTACHMENT
POINTS WITHIN THE TRUCK
BED ABLE TO WITHSTAND THE
PULLING FORCE OF LOADING.
THEY MUST ALSO BE TAUT
ENOUGH TO PREVENT THE RAMP
FROM COMING OFF THE VEHICLE
BEING LOADED.
Pull the loading ramp back until the6. chains are tight. The entire tongue
portion of the ramps must t onto
the tailgate; If not, adjust the Safety
Chains accordingly or shorter chains
must be used.
Chain Adjustment: Remove the7. bolt and washer that hold the safety
chain to the ramp. Reinsert the bolt
through a link that will shorten the
chain so the loading ramp can not
be pulled backwards by the ATV’s
rear tire. Tighten the bolt properly.
Make sure the washer prevents the
bolt from slipping through the chain
link. Adjust the other chain to equal
length.

Page 7For technical questions, please call 1-800-444-3353.SKU 44649
4- Wheel ATV Loading
WARNING!
THIS RAMP IS FOR USE WITH 2 OR• 4-WHEELED DIRT BIKES AND ATV’S
ONLY. DO NOT USE THIS RAMP TO
LOAD 3-WHEELED VEHICLES.
DO NOT USE THIS RAMP TO LOAD• ANY VEHICLE THAT WEIGHS MORE
THAN 1000 LB.
BE SURE THE TIRES OF THE ATV• BEING LOADED ARE NOT WIDER
THAN THE WIDTH OF THE RAMPS.
DO NOT USE THIS RAMP TO LOAD• ANY VEHICLE THAT IS CARRYING
GEAR ON ITS RACKS.
DO NOT USE THIS RAMP IF THE• TAILGATE ON THE VEHICLE BEING
LOADED IS HIGHER THAN HALF
THE RAMP’S LENGTH.
WARNING! All persons not involved in
the loading process must stand
clear of the loading Ramp and
truck. Keep pets away.
ONLY USE A WINCH (NOT
PROVIDED) TO LOAD THE
4-WHEEL ATV.
This is the safest way to load a1. 4-WHEEL ATV.
The winch and mounting/2. connection points must all have
appropriate capacity to pull the
ATV up the ramp safely.
Winch Setup:3.
ATV-Mounted:a. Unwind cable from
the winch and attach it to a secure
mounting location on the truck, at
the same height as the winch will be
after the ATV has been loaded.
Truck Mounted:b. Attach the cable to
the bottom front part of the frame.
While operating the winch, stand4. back and to the side of the ATV, with
the vehicle between you and the
winch cable.
WARNING! BE SURE THE 4-WHEELED
ATV IS CENTERED ON RAMPS.
Operate the winch to slowly load the5. ATV onto the vehicle.
Once load is in truck bed, be sure to6. set the ATV’s brake and securely tie
down ATV. Remove the ramp, fold it
up and secure it within the truck bed
using the Safety Chains and Hooks.
CAUTION: Contact between the tongue
(angled lip) of the ramp and the
tailgate of the vehicle may result in
damage to the vehicle’s body nish.

Page 8 For technical questions, please call 1-800-444-3353. SKU 44649
4- Wheel ATV Unloading
WARNING!
THIS RAMP IS FOR USE WITH 2• OR 4-WHEELED ATV’S ONLY. DO
NOT USE THIS RAMP TO UNLOAD
3-WHEELED VEHICLES.
DO NOT USE THIS RAMP TO• UNLOAD ANY VEHICLE THAT
WEIGHS MORE THAN 1000 LB.
DO NOT USE THIS RAMP TO• UNLOAD ANY VEHICLE THAT IS
WIDER THAN THE RAMPS, ADJUST
THE RAMPS BY MOVING THE ATV
CLOSE TO THE HAULING VEHICLE
AND ADJUSTING THE WIDTH
BEFORE PUTTING ANY WEIGHT ON
THE RAMPS.
DO NOT USE THIS RAMP TO• UNLOAD ANY VEHICLE THAT IS
CARRYING GEAR ON ITS RACKS.
DO NOT USE THIS RAMP IF THE• TAILGATE ON THE VEHICLE BEING
UNLOADED IS HIGHER THAN HALF
THE RAMP’S LENGTH.
WARNING! All persons not involved in
the unloading process must stand
clear of the loading Ramp and
truck. Keep pets away.
WARNING! RIDING AN ATV WHILE
UNLOADING IS DANGEROUS AND
SHOULD NOT BE ATTEMPTED.
Have a qualied adult assistant 1. monitor the Ramp tongue for slippage
on the tailgate.
Setup the ramp on the tailgate as2. explained under “Operation”, on page
6. Remove all tie down straps and
securing equipment from the ATV.
WARNING! ALIGN THE RAMPS ARE
WITH THE 4-WHEELED ATV’S
TIRES.
While staying off the ATV, start the3. engine, disengage the parking brake,
put the transmission into reverse,
and make sure the wheels are in a
straight line with the ramp. While
holding the brake, position yourself
on the truck bed in front of the ATV.
Release the brake and push on the4. ATV to get it started down the ramp.
Allow the ATV to roll down naturally,
do not attempt to steer it or apply the
brakes. If it stops while on the ramp,
gently give it throttle to back it off the
ramp.

Page 9For technical questions, please call 1-800-444-3353.SKU 44649
2-Wheel Bike Loading
Do not attempt to load any dirt bike1. or other 2-wheel motor bike alone.
Have a qualied adult assist.
Line up the 2-wheel bike with one of2. the Ramps.
With one person pushing the bike3. slowly up the Ramp, a helper should
be in the bed of the hauling vehicle
both to guide and to apply the brake
if it is necessary to stop the bike while
it is on the ramp. Have one person
with a hand on the bike hand brake
for safety.
Once the person inside the truck bed4. has hold of the handle bars, apply the
brake and steady the bike while the
other person moves behind the bike
(but off to one side) and pushes it all
the way into the truck bed.
NOTE: While most dirt bikes are light
enough to safely load with two
people, a third person can make the
job easier and safer.
Once the bike is safely loaded,5. secure it with four tie down straps
(not included), one on each side of
the front, and one on each side at the
rear of the bike.
2-Wheel Bike Unloading
Position the Ramp against the truck1. tailgate behind the rear tire of the
bike and attach the Safety Chain to
the truck bed.
Remove the tie-down straps (not2. included). Slowly and carefully while
using an assistant, push the bike
backwards until the back tire is at the
top of the Ramp. With one person on
the ground behind and to the side of
the Ramp, slowly push the bike onto
the Ramp. Someone must always
hold the hand brake.
Slowly work the bike down the Ramp3. and onto the ground.
Loading an Appliance Using a
Dolly
Make sure the ramps are clean of1. dirt, debris, grease and oil. Space the
ramps to match the dolly wheels.
The Tongue Edge must face down2. (see Assembly) fully contacting the
tailgate of the truck.
Position people according to the3. needs of the particular appliance.
As the dolly wheels contact the4. ramps, make sure the ramps remain
straight, and the tongue edges
remain in contact with the truck bed.
If not, roll back and slowly start over.
When unloading follow the same5. process in reverse.

Page 10 For technical questions, please call 1-800-444-3353. SKU 44649
MAINTENANCE
TO PREVENT
SERIOUS INJURY
FROM RAMP FAILURE:
Do not use damaged
equipment. If abnormal noise
or vibration occurs, have the
problem corrected before
further use.
BEFORE EACH USE,1. inspect the
general condition of the ramp. Check
for loose hardware, cracked or
broken parts, stress fractures, and
any other condition that may affect
its safe operation. Clean dirt, oil, or
any debris off ramps and tighten any
loose hardware before every use.
AFTER USE,2. wipe external surfaces
of the ramp with clean cloth.
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.