HAUL MASTER 94564 User manual

TRAILER
4’ x 8’
ASSEMBLY AND OPERATING INSTRUCTIONS
MODEL 94564
WARNING!
IMPORTANT INFORMATION
This trailer’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 tting 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 caus-
ing property damage, SERIOUS PERSONAL INJURY, or DEATH.
Diagrams within this manual may not be drawn proportionally.
Due to continuing improvements, actual product may differ slightly from the product described herein.
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©2006 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.
For technical questions or replacement parts, please call 1-800-444-3353.

Page 2SKU 94564 For technical questions, please call 1-800-444-3353.
CONTENTS
SPECIFICATIONS.................................................................................... 3
UNPACKING............................................................................................ 3
GENERAL SAFETY RULES.................................................................... 3
Work Area ..............................................................................................................3
Equipment Use and Care......................................................................................4
Service ...................................................................................................................5
SPECIFIC PRODUCT WARNINGS AND PRECAUTIONS ..................... 5
ASSEMBLY INSTRUCTIONS.................................................................. 7
Phase 1: .................................................................................................................7
Phase 2: .................................................................................................................8
Phase 3: .................................................................................................................9
Phase 4: .................................................................................................................9
Phase 5: ................................................................................................................10
Phase 6: ................................................................................................................10
Phase 8: ................................................................................................................13
Phase 9: ................................................................................................................14
Phase 10: ..............................................................................................................16
OPERATING INSTRUCTIONS ............................................................... 17
TIRE INFORMATION .............................................................................. 18
Tire Terminology Glossary..................................................................................18
Tire Markings........................................................................................................20
Tire Ination and Load Limit ...............................................................................21
TIRE CARE............................................................................................. 22
Checking Tire Pressure.......................................................................................22
Steps for Maintaining Proper Tire Pressure......................................................22
Tire Size ................................................................................................................23
Tire Tread..............................................................................................................23
Tire Rotation.........................................................................................................23
Tire Balance and Alignment................................................................................23
Tire Repair ............................................................................................................23
VEHICLE LOAD LIMIT ...........................................................................24
Steps for Determining Correct Load Limit.........................................................24
INSPECTION, MAINTENANCE, AND CLEANING ................................ 25
PARTS LISTS & ASSEMBLY DIAGRAM............................................... 26
LIMITED 90 DAY WARRANTY............................................................... 27

Page 3SKU 94564 For technical questions, please call 1-800-444-3353.
SPECIFICATIONS
Maximum Payload Capacity 1,720 Pounds
Bed Dimensions 4 Feet Wide x 8 Feet Deep
Required Hitch Ball Size (not included) 2”
Wheel Rim Diameter & Width 12” Diameter x 4” Wide
Tire Size & Type 5.30 – 12 / 6 P.R. / Load Range Rating C
Wheel Lug Nut Quantity
& Torque Requirement 5 Per Rim 85 to 90 Ft./Lbs.
Required Tire Air Pressure 80 PSI Per Tire Maximum (Cold)
Stop & Tail Light Type #1157 VDC (Clear)
Side Running Light Type #1895 VDC (Amber)
Ground Clearance 15-1/4” @ “Tongue / 17-1/2” @ Rear / 9-3/4” @ Axle
Overall Dimensions 139-1/4” Long x 62-1/4” Wide @ Fenders
25-1/2” High @ Top of Fenders
20-1/2” @ Deck Surface
Ship Weight / Net Weight 272 lbs. / 260 lbs.
UNPACKING
When unpacking, make sure all the parts and hardware shown on the Parts List/
Hardware List (page 19) are included. If any parts are missing or broken, please call Har-
bor Freight Tools at the number shown on the cover of this manual as soon as possible.
SAVE THIS MANUAL
You will need this manual for the safety warnings and precautions, assembly, oper-
ating, 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.
GENERAL SAFETY RULES
IMPORTANT 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 dam-
age to the Trailer, property damage, or SERIOUS PERSONAL INJURY.
SAVE THESE INSTRUCTIONS.
Work Area
Keep work area clean and dry. Cluttered, damp, or wet work areas invite injuries.1.
Keep children away from work area. Do not allow children to play in, climb on or2. ride in this product.
REV 09b

Page 4SKU 94564 For technical questions, please call 1-800-444-3353.
Store idle equipment. When not in use, tools and equipment should be stored in3. a dry location to inhibit rust. Always lock up tools and equipment, and keep out of
reach of children.
Do not use this product if under the inuence of alcohol or drugs. Read warning 4.
labels on prescriptions to determine if your judgement or reexes are impaired while
taking drugs. If there is any doubt, do not attempt to use this product.
Use eye protection. WearANSI-approved safety impact eye goggles when assem-5. bling this product. ANSI-approved safety impact eye goggles are available from
Harbor Freight Tools.
Dress safely. Do not wear loose clothing or jewelry, as they can become caught6. in moving parts. Wear a protective hair covering to prevent long hair from becom-
ing caught in moving parts. If wearing a long-sleeve shirt, roll sleeves up above
elbows.
Do not overreach. Keep proper footing and balance at all times to prevent tripping,7. falling, back injury, etc.
Industrial applications must follow OSHA requirements.8.
Stay alert. Watch what you are doing at all times. Use common sense. Do not use9. this product when you are tired or distracted from the job at hand.
Equipment Use and Care
Check for damaged parts. Before using this product, carefully check that it will1. 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 accessories: When servicing, use only identical replace-2. ment parts. Only use accessories intended for use with this product. Approved
accessories are available from Harbor Freight Tools.
Maintain this product with care. Keep this product clean and dry for better and3. safer performance.
Maintenance: For your safety, service and maintenance should be performed4.
regularly by a qualied technician.
Use the right equipment for the job. Do not attempt to force small equipment to do5. 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.

Page 5SKU 94564 For technical questions, please call 1-800-444-3353.
Service
Equipment service must be performed only by qualied repair personnel. Service 1.
or maintenance performed by unqualied personnel could result in a risk of injury.
When servicing equipment, use only identical replacement parts. Follow instruc-2. tions in the “Inspection, Maintenance, and Cleaning” 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
To avoid personal injury and/or property damage, do not exceed the Trailer’s maxi-1. mum payload capacity of 1,720 pounds (evenly distributed).
Before each use, always examine the Trailer for proper Tire air pressure (maximum2. pressure is 80 PSI cold), damaged tail lights, 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 Trailer even if minor damage appears.
Never allow adults, children, or pets to ride in or play on the Trailer.3.
Before each use, always attach the Safety Chain of the Trailer to the towing vehicle.4. Make sure the Safety Chain is attached to the towing vehicle with the same length
for each side. Do not allow the Safety Chain to drag on the ground.
Always check to make sure the payload being transported is properly and safely5. secured in the Trailer. Load the Trailer evenly from side to side with 60% of the
load forward of the Axle.
Prior to using the Trailer, make sure to read and understand all instructions and6. safety precautions as outlined in the owner’s manual for the towing vehicle. Make
sure the towing vehicle is capable of towing the Trailer and its payload. Make sure
the hitch on the towing vehicle is capable of towing the Trailer and its payload. The
towing capacity of the hitch is typically stamped on the hitch drawbar.
Make sure the Coupler and the vehicle’s ball hitch (not included) are of equal mat-7. ing size (2”) and are rated equal to or greater than the weight of the Trailer and its
payload.
Do not exceed 45 miles per hour when towing the Trailer. Excess speed is a major8. cause of vehicle-trailer accidents.
The Tail Light Bulbs supplied with this Trailer are for a 12 volt DC electrical system9. only. Do not attempt to power the Light Bulbs with any other type or voltage elec-
trical current.
Whenever possible, park the Trailer on a at, level, paved, surface and chock both 10. Tires to keep the Trailer from accidently moving.
REV 09b

Page 6SKU 94564 For technical questions, please call 1-800-444-3353.
11. CAUTION! Care must be taken when backing up the Trailer. Only back up
the Trailer on a straight path. If the Trailer is allowed to turn off the straight path
while backing up, the Trailer could jackknife, causing severe damage to the Trailer
and towing vehicle.
Maintain labels and nameplates on the Trailer. These carry important information.12. If unreadable or missing, contact Harbor Freight Tools for a replacement.
Reporting safety defects: If you believe your Trailer has a defect which could cause13. a crash or could cause injury or death, you should immediately inform the National
Highway Trafc Safety Administration (NHTSA) in addition to notifying the manufac-
turer, Changzhou Nanxiashu Tool Company. If NHTSAreceives similar complaints,
it may open an investigation, and if it nds that a safety defect exists in a group of
vehicles, it may order a recall and remedy campaign. However, NHTSA can not
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.
Trailer licensing notice: Some states may consider this Trailer a vehicle requiring14. registration, licensing, and titling. Check with your State Department of Motor Vehi-
cles for information and guidance on registering, licensing, and titling the Trailer.
WARNING: The warnings, precautions, and instructions discussed in this manual15. 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.
This Trailer must be securely connected to the towing vehicle before16. loading.

Page 7SKU 94564 For technical questions, please call 1-800-444-3353.
ASSEMBLY INSTRUCTIONS
Phase 1:
FRONT END OF TRAILER
FIGURE A
Parts Needed
Part # Description Qty.
1FL Front Left Side Rail 1
1FR Front Right Side Rail 1
2A Cross Member 1
2B Cross Member 2
A M10 x 20 Bolt 8
I M10 Nylon Nut 8
Lay out the Front Left Side Rail (1FL), Front Right Side Rail (1FR), one Cross Mem-
ber (2A), and two Cross Members (2B). Assemble these parts, using the M10 x 20
Bolts (A) and M10 Nylon Nuts (I). (See Figure A.)

Page 8SKU 94564 For technical questions, please call 1-800-444-3353.
Phase 2:
FIGURE B
2B
2B
2A
Parts Needed
Part # Description Qty.
3L Left Connecting Rail 1
3R Right Connecting Rail 1
4 Angle Iron 2
5 T-Plate 1
6 Coupler Base 1
9 L-Latch 2
A M10 x 20 Bolt 8
B M10 x 25 Bolt 6
F M14 x 30 Bolt 2
I M10 Nylon Nut 14
J M14 Nylon Nut 2
R 3mm R-Pin 2
1. Attach an Angle Iron (4) to the Front Left and Front Right Side Rails (1FL, 1FR) and
Cross Member (2B), using the M10 x 20 Bolts (A) and M10 Nylon Nuts (I).
(See Figure B.)
Attach the Left and Right Connecting Rails (3L, 3R) to the Cross Member (2B), us-2. ing the L-Latch (9) and 3mm R-Pin (R). Then attach the Left and Right Connecting
Rails to the Angle Irons (4), using the M14 x 30 Bolts (F) and M14 Nylon Nuts (J).
(See Figure B.)
Attach the Coupler Base (6) to the Left and Right Connecting Rails (3L, 3R), using3. the M10 x 25 Bolts (B) and M10 Nylon Nuts (I). Then attach the T-Plate (5) under
the Left and Right Connecting Rails, using the M10 x 25 Bolts (B) and M10 Nylon
Nuts (I). (See Figure B.)

Page 9SKU 94564 For technical questions, please call 1-800-444-3353.
Phase 3:
FIGURE C
Parts Needed
Part # Description Qty.
1RL Rear Left Side Rail 1
1RR Rear Right Side Rail 1
2B Cross Member 3
A M10 x 20 Bolt 10
I M10 Nylon Nut 10
1. Lay out the Rear Left Side Rail (1RL), Rear Right Side Rail (1RR), and three Cross
Members (2B). (See Figure C.)
Assemble the Rear Left Side Rail (1RL), Rear Right Side Rail (1RR), and three2. Cross Members (2B), using the M10 x 20 Bolts (A) and M10 Nylon Nuts (I).
(See Figure C.)
Phase 4:
Parts Needed
Part # Description Qty.
A M10 x 20 Bolt 2
I M10 Nylon Nut 2
FIGURE D
Assemble the front portion and rear portion, using the M10 x 20 Bolts (A) and
M10 Nylon Nuts (I). (See Figure D.)

Page 10SKU 94564 For technical questions, please call 1-800-444-3353.
Phase 5:
With assistance, turn the frame upside down.1.
FIGURE E
12L
1FL
Parts Needed
Part # Description Qty.
12L Left Spring Hanger 1
12R Right Spring Hanger 1
B M10 x 25 Bolt 6
C M10 x 30 Bolt 2
H M10 x 30 Carriage Bolt 4
I M10 Nylon Nut 12
2. Attach the Left Spring Hanger (12L) to the Front Left Side Rail (1FL), using the M10
x 25 Bolts (B) and M10 Nylon Nuts (I). (See Figure E.)
Attach the Right Spring Hanger (12R) to the Front Right Side Rail (1FR), using the3. M10 x 25 Bolts (B) and M10 Nylon Nuts (I). (See Figure E.)
Attach the Left Spring Hanger (12L) to the Rear Left Side Rail (1RL), using the M104. x 30 Bolts (C), M10 x 30 Carriage Bolts (H), and M10 Nylon Nuts (I).
(See Figure E.)
Attach the Right Spring Hang-5. er (12R) to the Rear Right
Side Rail (1RR), using the
M10 x 30 Bolts (C), M10 x 30
Carriage Bolts (H), and M10
Nylon Nuts (I).
(See Figure E.)
Phase 6:
Attach a Fender Seat (23) to1. the Left Spring Hanger (12L),
using the M10 x 20 Bolts (A)
and M10 Nylon Nuts (I).
(See Figure F.)
Attach the remaining Fender2. Seat (23) to the Right Spring
Hanger (12R), using the M10
x 20 Bolts (A) and M10 Nylon
Nuts (I). (See Figure F.)
FIGURE F
Parts Needed
Part # Description Qty.
14 Spring Plate 2
15 Spring 2
16 Axle 1
17 U-Bolt 4
22 Fender 2
23 Fender Seat 2
Parts Needed
Part # Description Qty.
A M10 x 20 Bolt 8
G M14 x 80 Bolt 4
I M10 Nylon Nut 16
K M14 Hex Nut 4
S 3mm Cotter Pin 4

Page 11SKU 94564 For technical questions, please call 1-800-444-3353.
Attach a Fender (22) to the left Fender Seat (23), using the M10 x 20 Bolts (A) and3. M10 Nylon Nuts (I). (See Figure F.)
Attach a Fender (22) to the right Fender Seat (23), using the M10 x 20 Bolts (A)4. and M10 Nylon Nuts (I). (See Figure F.)
On each side, place a Spring (15) on the Spring Hangers (12L, 12R) with the spring5. eyes forward. Insert an M14 x 80 Bolt (G) through the Springs, and secure the Bolts
with M14 Nuts (K) and 3mm Cotter Pins (S). (See Figure F.)
Place the Axle (16) on top of the Springs (15). Place a Spring Plate (14) under the6. Springs. Insert a U-Bolt (17) through the Axle, Springs, and Spring Plates. Secure
the Axle with M10 x 20 Bolts and M10 Nylon Nuts (G) screwed onto the U-Bolts.
(See Figure F.)
Phase 7:
IMPORTANT: Whenever a Hub (18) on a new Trailer requires assembly (or if a Hub1. is disassembled for maintenance) the following procedures MUST be followed:
19
18
31
L
21
M
O
20
T
NOTE:
Periodically, grease the Seal (99)
on the backside of the Hub (18)
FIGURE G
Parts Needed
Part # Description Qty.
18 Hub 2
19 Tire/Wheel Assy. 2
20 Bearing 2
21 Dust Cap 2
31 Grease Fitting 2
L M12 Lug Nut 10
M M20 Castle Nut 2
O 20 Flat Washer 2
T 4mm Cotter Pin 2
a. Using a suitable solvent, thoroughly clean the Hub (18), Bearings (20), Castle
Nut (M), Dust Cap (21), and the rest of the parts of the Hub Assembly of all
grease, dirt, metal shavings, and all other foreign objects. These parts must be
cleaned, even if they are new or appear to be clean.
(See Figure G.)
Allow all parts to dry completely.b.
Make sure your hands are clean and the bearing packer (not included) isc. clean.
Place fresh, clean bearing grease in the bearing packer.d.

Page 12SKU 94564 For technical questions, please call 1-800-444-3353.
With the grease-lled bearing packer in one hand and the Bearings (20) in the e. other, press the Bearing into the grease, forcing the grease inside the slots in
grease, forcing the grease inside the slots in the Bearing. Continue doing this
until every slot in the Bearing is completely full of grease.
(See Figure G.)
Finish assembling the Hub Assembly as explained below, making sure not tof. get dirt or debris on any part of the assembly.
Carefully slide the Hubs (18) over the spindles at each end of the Axle (16).2. (See Figure G.)
Insert the Bearings (20) and Flat Washers (O) on the spindles. Screw an M203. Castle Nut (M) tightly onto each spindle. Then back the Castle Nut off slightly so
that the Hubs can just move freely. (See Figure G.)
Insert a 4mm Cotter Pin (T) through the M20 Castle Nut (M) and hole at the end of4. each spindle, and spread the Cotter Pins. (See Figure G.)
Fill the Dust Caps (21) with bearing grease. Then, press each Dust Cap onto the5. Hubs (18). (See Figure G.)
Grease each Grease Fitting (31) located on the backside of each Hub (18).6. (See Figure G.)
Install a Tire/Wheel (19) assembly on each Hub Set (18). Then, secure the Tire/7. Wheel assemblies, using the M12 Lug Nuts (L). (See Figure G.)
Note: Use a lug wrench (not included) to tighten the M12 Lug Nuts (in a “star” pattern) to
85 to 90 ft-lb. (See Figure G.)

Page 13SKU 94564 For technical questions, please call 1-800-444-3353.
Phase 8:
With assistance, turn the Trailer assembly right side up.1.
Parts Needed
Part # Description Qty.
7 Coupler 1
8 Safety Chain 1
24 Side Running Light 2
26 Tail Light Bracket 2
27 License Plate Bracket 1
28L Left Tail Light 1
28R Right Tail Light 1
29 Safety Pin 1
A M10 x 20 Bolt 4
D M12 x 40 Bolt 1
E M12 x 90 Bolt 2
N 10 Flat Washer 1
P 4mm Self Tapping Screw 4
Q 2mm R-Pin 1
U M12 Nylon Nut 4
V M12 x 20 Bolt 1
FIGURE H
2. Attach the Coupler (7) to the Coupler Base (6), using the M12 x 90 Bolts (E) and
M12 Nylon Nuts (U). Insert an M10 x 25 Bolt (B) downward through the rear hole
of the Coupler and Coupler Base and screw on an M10 Nylon Nut (I).
(See Figure H.)
Lock the Coupler (7) Trigger, using a Safety Pin (29) and 2mm R-Pin (Q).3. (See Figure H.)
Attach the Safety Chain (8) to the Coupler (7) with an M12 x 40 Bolt (D) inserted4. through the center link of the Safety Chain. Then secure the Safety Chain in place,
using a Flat Washer (N) and M12 Nylon Nut (U). (See Figure H.)
Assemble the Tail Light Brackets (26) to the rear of the Rear Left Side Rail (1RL)5. and Rear Right Side Rail (1RR), using the M10 x 20 Bolts (A) and M10 Nylon Nuts
(I). (See Figure H.)
REV 07j

Page 14SKU 94564 For technical questions, please call 1-800-444-3353.
Attach the License Plate Bracket (27) with the Left Tail Light (28L) to the Rear Left6. Side Rail (1RL), using the M10 x 20 Bolts (A) and M10 Nylon Nuts (I).
NOTE: The Left Tail Light has a clear window at the bottom. (See Figure H.)
Attach the Right Tail Light (28R) to the rear of the Right Side Rail (1RR), using the7. M10 x 20 Bolts (A) and M10 Nylon Nuts (I). (See Figure H.)
Open the Lens of the Side Running Lights (24). Run the Wire Lead of a Side Run-8. ning Light through the center hole located at the front end of the Front Left Side
Rail (1FL). Then attach the Side Running Light to the Front Left Side Rail, using
the 4mm Self Tapping Screws (P). (See Figure H .)
Run the Wire Lead of the remaining Side Running Light (24) through the center9. hole located at the front end of the Front Right Side Rail (1FR). Then attach the
Side Running Light to the Front Right Side Rail, using the Self Tapping Screws (P).
(See Figure H.)
Re-install the Lens on the two Side Running Lights (24). (See Figure H.)10.
Phase 9:
Have a qualied service technician install a 4-wire, 12 volt DC Connector in the 1. trunk area of your vehicle.
TAIL LIGHT ILLUM.
RUNNING LIGHT (BROWN)
GROUND (WHITE)
GROUND (WHITE)
U
CONNECTOR YELLOW
F
BROWN
WIRE
(FROM LIGHT)
C
F
BROWN YELLOW
RED
BLACK
C
D
L.H. STOP & TURN
R.H. STOP & TURN (GREEN)
GREEN
E
E
CONNECTOR
WIRE
(FROM LIGHT)
BROWN
WIRE CLIP
D
GREEN
BROWN
BLACK
RED
B
B
AA
FIGURE I
2. Locate the vehicle’s Connector Plug near the Trailer’s Coupler (7) and lay out the
Trailer’s Wiring Harness wires. (See Figure I.)

Page 15SKU 94564 For technical questions, please call 1-800-444-3353.
Connect the Brown Wire to the vehicle’s Left Tail Light by stripping, wrapping, and3. taping the Connector Plug. (See Figure I.)
Connect the Yellow Wire to the vehicle’s Left Signal and Stop Light Wire.4. (See Figure I.)
Connect the Green Wire to the vehicle’s Right Signal and Stop Light Wire.5. (See Figure I.)
NOTE: Some foreign vehicles may require an adaptor to convert their 5-wire system6. to a 4-wire vehicle Connector Plug. (See Figure I.)
Attach the White Ground Wire at the plug end of the Wiring Harness to the small7. hole on the Coupler Base (6) with a 1/4” Tapping Screw (not included).
(See Figure I.)
Leave about 18” of wire beyond the Coupler (7). Then lay out the remaining wires8. along the Connecting Rails (3L, 3R) and Left and Right Side Rails (1FL, 1FR, 1RL,
1RR). (See Figure I.)
Secure the wires to the Connecting Rails (3L, 3R) and Left and Right Side Rails9. (1FL, 1FR, 1RL, 1RR), using the Clips provided. (See Figure I, Circle D.)
Connect the Wire Lead from the Side Running Light (24) on each side of the Trailer10. to the Brown Wire of the Wiring Harness, using a Wire Connector.
(See Figure I, Circle E.)
Strip about 3/4” of the ends of the Yellow/Brown and Green/Brown wires.11. (See Figure I.)
Make the following connections (per color code). (See Figure I, Circle C.)12.
Left Side Right Side
Yellow-Red Wire Green-Red Wire
Brown-Two Black Wires Brown-Two Black Wires

Page 16SKU 94564 For technical questions, please call 1-800-444-3353.
Phase 10:
48”
48”
3/4” THICK PLYWOOD
3/4” THICK PLYWOOD 3/8”
CARRIAGE BOLT
3/8”
WASHER
3/8”
LOCK WASHER*
3/8”
NUT
3/8”
HARDWARE
&
PLYWOOD
(NOT INCLUDED)
FIGURE J
48”
1. To install a Bed for the Trailer, cut two pieces of 3/4” thick plywood (not included)
at 48” x 48”. NOTE: It may be necessary to slightly trim the plywood to t.
(See Figure J.)
Mark 7 locations in each piece of plywood to correspond with the 14 mounting holes2. located on the front and rear Cross Members (2A, 2B) and Left and Right Side Rails
(1FL, 1FR, 1RL, 1RR). Set the plywood aside, and drill the 14 marked locations
with a 3/8” bit. Then, replace the plywood on the Trailer frame. (See Figure J.)
Secure the two pieces of plywood to the front and rear Cross Members (2A, 2B) and3. Left and Right Side Rails (1FL, 1FR, 1RL, 1RR), using 3/8” diameter, rust resistant
Carriage Bolts, Washers, Lock Washers, and Nuts (none included). Make sure the
bolt heads do not protrude up through the plywood. (See Figure J.)

Page 17SKU 94564 For technical questions, please call 1-800-444-3353.
OPERATING INSTRUCTIONS
1. Only use a 2” Ball Hitch (not included) on the towing vehicle. (See Figure K.)
NOTE: To reduce friction between the 2” Ball Hitch and Trailer Coupler (7), apply2. a layer of heavy grease over the Ball Hitch. (See Figure K.)
2mm R-PIN (Q)
SAFETY PIN (29)
HITCH
TRIGGER
COUPLER
(7)
SLOT
HANDLE
ADJUSTMENT
NUT
2” BALL
HITCH
FIGURE K
3. Temporarily remove the 2mm R-Pin (Q) and Safety Pin (29). Then, pull up on the
Trigger and lift up on the Handle. (See Figure K.)

Page 18SKU 94564 For technical questions, please call 1-800-444-3353.
4. With assistance, place the Hitch Coupler (7) 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 tting snugly
in the Coupler.
There should be no play between the Hitch Ball and 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. (See
Figure K.)
Re-install the Safety Pin (29) and 2mm R-Pin (Q).5.
Make sure to attach each side of the Safety Chain (8) equally to6. the towing vehicle’s rear bumper or frame. (See Figure K.)
Connect the Tail Light Wiring Assembly to the towing vehicle’s 12 Volt DC wiring7. connector. NOTE: Make sure to consult the operator’s manual of the towing vehicle
for proper connection instructions.
8. CAUTION! Care must be taken when backing up the Trailer. Only back up
the Trailer on a straight path. If the Trailer is allowed to turn off the straight path
while backing up, the Trailer could jackknife, causing severe damage to the Trailer
and to the towing vehicle.
When towing the Trailer over long distances stop and check the tightness of all9. connections, Side Running Lights (24), and Tail Lights (28L, 28R) at least every
100 miles.
Carry emergency ares, and re extinguisher, if required for operation in your state. 10. Carry extra bulbs and fuses if towing the Trailer at night over long distances.
Trigger on
locking handle
MUST latch in
place before
inserting
safety pin.
TIRE INFORMATION
Tire Terminology Glossary
Accessory weight means• - the combined weight of automatic transmission, power steering, 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 deect 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 carcass, tread, or any components that connect the tire to the
wheel center member.

Page 19SKU 94564 For technical questions, please call 1-800-444-3353.
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 additional 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 kilograms 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 con-
sidered 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 distrib-
uting 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.

Page 20SKU 94564 For technical questions, please call 1-800-444-3353.
Tire Markings
Load index and
Speed rating*
European tire
certicate*
U.S. DOT tire
identication
number
*Information not required by U.S. DOT
Inner diameter
in inches
Section width
in inches
Trailer
tire
Maximum
load rating
Tire ply
composition
and materials
used
Maximum
permissible
ination
pressure
Section width• - This number gives the width of the tire in inches. The larger the number, the wider the
tire. (The markings on the example tire diagram show 4.80. The markings on your tire may differ.)
Inner diameter• - This number gives the inner diameter of the tire in inches. This is also the rim diameter in
inches. (The markings on the example tire diagram show 12. The markings on your tire may differ.)
U.S. DOT tire identication 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 indicates the maximum load in kilograms and pounds that can
be carried by the tire.
Code Pounds
71 761
72 783
73 805
74 827
75 853
76 882
77 908
78 937
Code Pounds
79 963
80 992
81 1,019
82 1,047
83 1,074
84 1,102
85 1,135
86 1,168
Code Pounds
87 1,201
88 1,235
89 1,279
90 1,323
91 1,356
92 1,389
93 1,433
94 1,477
Code Pounds
95 1,521
96 1,565
97 1,609
98 1,653
99 1,709
100 1,764
101 1,819
102 1,874
Code Pounds
103 1,929
104 1,984
105 2,039
106 2,094
107 2,149
108 2,205
109 2,271
110 2,337
Load Index Rating Codes
• Load index- This is a measurement of how much weight each tire can support. See chart above. (The
markings on the example tire diagram show 71. The markings on your tire may differ.) Note: You may
not nd this information on all tires because it is not required by law.