HAUL MASTER 38897 User manual

Assembly and Operating Instructions
3491 Mission Oaks Blvd., Camarillo, CA 93011
Copyright 1998 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 and replacement parts, please call 1-800-444-3353.
Model 38897
Trailer Cart
(10 Cubic Feet)
Revised Cover 12/04
®

Thank you for choosing a Harbor Freight Tools product! For future reference, please complete the owner’s
record below:
Model:___________________ Purchase Date:_________________
Save the receipt, warranty card and these instructions. It is important that you read the entire instruction sheet
to become familiar with this product before you begin using it.
Technical Specifications:
This heavy duty Trailer Cart has a large 10 cubic foot bed capacity. It has a tail gate
which is easy to lift out, and the the bed tilts with a quick release feature.
Cart Dimensions: 43” x 33” x 12”; Inside Bed Dimensions: 41” x 30” x 12”
16” Wheels with Pneumatic Tires; Pin Hitch: #5/8” Pin Hole
Trailer Cart Capacity: 600 Lbs.
Warning:
1. Always wear ANSI approved safety goggles when assembling this product and when
working with tools and equipment.
2. The Trailer Cart has a safe working capacity of 600 lbs. Never exceed this
weight capacity.
3. When unloading and loading the cart, be careful of the balance of the cart. Always
engage the tongue latch to the towing vehicle before loading the Trailer Cart. The cart will
ride best with the load centered over and in front of the axle.
4. Never allow children to play in or operate the cart. This cart is not designed for carry-
ing people or animals.
5. This Trailer Cart is not designed for use on public highways. Always use low speeds
(under 5 MPH) when performing off road hauling.
6. Before each use, check the tongue latch connection to the towing vehicle to insure safe
operation. Before each use, check the condition of pneumatic tires (recommended tire
pressure is 30 PSI).
#38897 Page 2

Assembly of the Trailer Cart
The Trailer Cart requires a good deal of assembly, but with the right tools and careful reading of this manual,
assembly should be fairly routine. You will need a regular screwdriver, pair of pliers, two 14 mm. open end
wrenches and two 13 mm. open or box end wrenches (similar size ratchet wrenches will speed assembly).
Part numbers shown below refer to the Part Number Listing on page 9.
Hardware
Required hardware needed to assemble
the Trailer Cart is shown below:
It is recommended that all the parts be put
out on a flat surface before beginning to
assemble the Trailer Cart. Check to see that
all parts shown in this manual are present
(refer to parts illustrations and the part number
listing on page 9). If any parts are missing
or in damaged condition, please call Harbor
Freight Tools at the telephone number shown
on the cover of this manual.
Step 1: Lay out the two Bottom Panels (#1)
as shown in Figure 1 below. Attach the Front
Cross Brace (#2) to the Bottom Panels using
4 Bolts (#21), 4 Washers (#23) and 4 Nuts
(#24).
Figure 1
Step 2: Connect the two Bottom Panels shown in Figure 2 using 4 Bolts (#21), 4 Washers (#23) and 4 Nuts
(#24).
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Bottom Panels
(#1)
Front Cross
Brace (#2)

Figure 2
Bolt Locations
Step 3: Attach the Tongue Support (#3) to the Bottom
Panels using 2 Bolts (#22), 2 Washers (#23), and 2 Nuts
(#24) - see Figure 3.
Figure 3
Step 4: As shown in Figure 4 below, bolt the 2 WheelAxle Supports together using 8 Bolts (#25), 8 Washers
(#23) and 8 Nuts (#24). Note: Only hand tighten these 8 Bolts (#25) now, Bolts should be securely tightened
once WheelAxle is installed (see Step 6, page 5).
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Bottom Panels
(#1)
Tongue Support
(#3)
Figure 4
WheelAxle Supports
(#4)
REV 02/07

#38897 Page 5
Figure 5
Step 5: Bolt the Wheel Axle Supports (#4) to the
Bottom Panels (#1) using 8 Bolts (#21), 8 Washers
(#23), and 8 Nuts (#24) - see Figure 5
Figure 6
Figure 7
Step 6: As shown in Figure 6, put the Hitch Tongue in place and insert the WheelAxle (#5) throught the Wheel
Axle Support (#4). Install the 2 Wheel/TireAssemblies (#6) with Washers (#26) and Cotter Pins (#27).
Step 7: As shown in Figure 7, insert the Tongue Latch (#9)
up through the opening in the Hitch Tongue (#10). Using
a Latch Spacer (#8) on each side of the Tongue Latch, bolt
the Latch Spacer to the Hitch Tongue using Bolt (#29) and
Nut (#30). Only hand tighten this bolt for now.
Attach one end of the Latch Spring (#7) to the
opening in the Hitch Tongue (#10) and the other end
to the top hole in the Latch Spacer (#8). With the
Latch Spring in place, tighten the bolt described
in the above paragraph.
Wheel Axle (#5)
Wheel/Tire
Assembly (#6)
Hitch Tongue (#10)
Tongue Latch (#9)
Latch Spacer (#8)
Latch Spring (#7)
Hitch Tongue (#10)
REV 02/07

Figure 8
Step 8: As shown in Figure 8, install the Hitch Pin Bracket
(#11) by using 2 Bolts (#25), 2 Washers (#23), and 2 Nuts
(#24) in the rear most two holes. The Hitch Pin (#28) fits in
the front hole, and is secured in place with a Cotter Pin (#27).
Figure 9
Step 9: Turn the Trailer Cart over onto it’s wheels. To the rear portion of the Bottom Panels (#1), attach the
Rear Corner Brackets (#13) and the Rear Cross Brace (#12), by using 4 Bolts (#21), 4 Washers (#23) and 4
Nuts (#24).
Figure 10
Step 10: As seen in Figure 10, assemble the
left Side Panel (#14) using 2 Bolts (#21),
2 Washers (#23) and 2 Nuts (#24). Insert
bolts in the holes shown. See Step 13,
page 7 for instructions on installing 2 other
bolts into Side Panel.
Bottom Panels
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Hitch Pin Bracket (#11)
Hitch Tongue (#10)
Rear Corner Brackers (#13)
Rear Cross Brace (#12)
Side Panel (#14)
REV 02/07

Figure 11
Step 11: See Figure 11 for bolt positions. Bolt Rear
Cross Brace (#12) to Bottom Panels (#1) using 6 Bolts
(#21), 6 Washers (#23) and 6 Nuts (#24).
Figure 12
Rear Cross Brace (#12)
Bottom Panel (#1)
Step 12: Install the right Side Panel (#14)
to the Bottom Panel (#1) as shown in Figure
12. Use 2 Bolts (#21), 2 Washers (#23), and
2 Nuts (#24) to attach the Side Panel.
See Step 13 below for instructions on
installing 2 other bolts into side panel.
Bolt Locations
Rear Corner Brace (#15)
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Step 13: Secure each Side Panel (#14) by
bolting a Rear Corner Brace (#15) to the
outside of the Side Panel. Use 5 Bolts (#21),
5 Washers (#23) and 5 Nuts (#24) to secure
each Side Panel. Figure 13 shows Rear
Corner Brace being assembled to
left Side Panel. Follow same
procedure to assemble Rear Corner
Brace to right Side Panel.
Figure 13
REV 02/07

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Step 14: Assemble the Front Panel (#16)
to the Front Cross Brace (#2) and the two
Side Panels (#14) by using 12 Bolts (#21),
12 Washers (#23) and 12 Nuts (#24). Bolt
positions are shown in Figure 14 at right.
Figure 14
Figure 15
Step 15: Assemble the two Front Corner Braces
(#17) to the corners of the Front Panel and the
Side Panels (see Figure 15). For each Front Corner
Brace use 2 Bolts (#21), 2 Washers (#23) and 2
Nuts (#24).
Figure 16
Tailgate Latch (#18)
Tailgate (#20)
Step 16: Attach the two Tailgate
Latches (#18) to the inside of the
Tailgate (#20) using 2 Bolts (#21),
2 Washers (#23) and 2 Nuts (#24)
for each Tailgate Latch (see Figure 16).
Insert the two Tailgate Pins (#19) through
the two holes in lower portion of the Tailgate,
and secure the Tailgate Pins by adding a Washer
(#32) and a Nut (#31) to the threaded portion.
The Tailgate is now ready to be put in place on the Trailer
Cart. Position the Tailgate so that the two Tailgate Pins can be
dropped into the two holes on the Rear Cross Brace (#12). The
Tailgate Latches can now be dropped over the open slots in each Side Panel which will lock the Tailgate in
place. Assembly of the Trailer Cart is complete. Before using the cart make sure all hardware connections are
tight.
(view of inside)
Front Corner Brace (#17)

Part Number Listing
Part # Reference # Description Qty
1 234A1 Bottom Panel 2
2 234A2 Front Cross Brace 1
3 234A3 Tongue Support 1
4 234A4 Wheel Axle Support 2
5 234A5 Wheel Axle 1
6 234A6 Wheel/TireAssembly 2
7 234A7 Latch Spring 1
8 234A8 Latch Spacer 2
9 234A9 Tongue Latch 1
10 234A10 Hitch Tongue 1
11 234A11 Hitch Pin Bracket 1
12 234A12 Rear Cross Brace 1
13 234A13 Rear Corner Bracket 2
14 234A14 Side Panel 2
15 234A15 Rear Corner Brace 2
16 234A16 Front Panel 1
17 234A17 Front Corner Brace 2
18 234A18 Tailgate Latch 2
19 234A19 Tailgate Pin 2
20 234A20 Tailgate 1
Hardware
21 234B1 M8x16 Truss Head Bolt 60
22 234B2 M8x20 Truss Head Bolt 2
23 234B3 8mm Lock Washer 72
24 234B4 8mm Hex Nut 72
25 234B5 M8x20 Hex Head Bolt 10
26 234B6 20mm Flat Washer 2
27 234B7 3mm Cotter Pin 3
28 234B8 12.5x 64 Hitch Pin 1
29 234B9 M6x90 Hex Head Bolt 1
30 234B10 6mm Nylon Nut 1
31 234B11 6mm Hex Nut 2
32 234B12 6-8mm Flat Washer 2
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