Let's Go Aero LittleGiant Trailer TLK864 Installation instructions

Save ThiS Manual
Read the owner’s manual over carefully before you begin using your trailer. You will need
this manual for the safety warnings and precautions, operating procedures, parts list,
inspection, and maintenance information. Keep this manual for continued reference.
liTTleGianT Trailer™
TlK864 (7’ Torsion based & related models)
User Assembly and Operation Manual
Visit our website at www.LetsGoAero.com For Assistance, please call 1-877-464-2376 or 719-630-3800
Safe uSe & OperaTiOn pg. 2
SafeTy CheCKliST pg. 2
inSpeCTiOn, MainTenanCe
and CleaninG pg. 3
parTS idenTifiCaTiOn pg. 9,10
liTTleGianT Trailer aSSeMbly pg. 12
WarranTy / repair prOCedureS pg. 21
Trailer liCenSinG nOTiCe pg. 21
TLK684 081715

Safe uSe & OperaTiOn
Be sure to follow these guidelines to prevent possible hazards from misuse.
Do NOT exceed the trailer’s maximum load weight capacity of 1,500 lbs. or exceed the trailer’s bed size.
The Gross Vehicle Weight Rating (G.V.W.R.) for the LittleGiant™ Trailer is 1,920 lbs, and is calculated as
follows:
The Empty Weight of the Trailer (420 lbs) + the maximum payload the trailer can carry
(1,500 lbs) = 1,920 lbs G.V.W.R.
2. Make sure the towing vehicle as well as the hitch is capable of towing the trailer and its payload. Check your vehicle
and hitch owner’s manual for tow ratings.
3. The tail light bulbs supplied with this trailer 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.
4. Always check to make sure the payload being transported is properly and safely secured in the trailer. Never place
loads on one side only. Load the trailer evenly from side to side with 60% of the load forward of the axle (the tongue
weight is 10% of the load, which does not include the weight of the trailer. The load is divided so that 90% of the load
is over the axle and 10% is over the tongue). See diagrams below:
Before Each Use
Trailers are generally not used everyday. Your trailer may sit for extended periods of time between uses making it very
important to check all components thoroughly before each use. Following these simple instructions will maximize the life of
your trailer and keep you safely transporting your cargo.
• Inspect the general condition of the trailer. Check for loose bolts and nuts, misalignment or binding of moving parts,
cracked, bent, or broken parts, excessively worn safety cable, damaged tail lights/side running lights/wire harness,
loose lug nuts, loose hitch connection, and any other condition that may affect its safe operation.
• Check your maintenance schedule to ensure that all routine maintenance matters are current. Perform any neglect-
ed maintenance by a qualied technician.
• Always check wheel lug nuts for proper tightness. When using trailer for the rst time, check wheel lug nuts for
proper tightness at 50 miles of travel. Before every subsequent use and at 500 mile intervals during every trip, check
and tighten the tire lug nuts. Always ensure wheel bolts are tight. Torque to 50 – 75 ft.-lbs.
• Check the tires for wear and the tire pressure for proper ination (30 PSI).
• Check the operation of all lights. Replace any faulty bulbs. Operating lights are mandatory on a trailer. Periodically
check lighting when towing over long distances. Check the tightness of all connections.
• Make sure wiring is properly installed and secured to trailer to prevent from hanging and catching on any road debris.
• Make sure the safety cables are attached to the trailer and the towing vehicle. Criss-cross cables as necessary to
prevent from hanging and catching on any road debris.
• Check and adjust your tow vehicle’s tow height to make sure that the trailer is being towed level.
• Check that the trailer coupler is fastened securely onto the trailer ball. The LittleGiant Trailer is equipped with a 2"
coupler and must be used with a 2" trailer ball. After assembly and attachment, pull up and down on the coupler to
make sure the hitch ball is tting snugly in the coupler. If the coupler is not secured properly, the ball could come
loose while the trailer is in motion, possibly causing property damage, serious injury or death.
Center Load from
Side to Side
60% of Load
Forward of Axle
90% of Load
Over Axle
Page 2 of 21

WARNINGS
Failure to adhere to these recommendations may result in potential hazards from improper operation, including prop-
erty damage and bodily injury.
• Keep children away. Be sure children are kept a safe distance from the trailer operating area.
• Never ride on the trailer. Serious injury or death could occur.
• Whenever possible, park the trailer on a at, level, paved surface and chock both tires to keep the trailer from
accidently moving.
• When driving do not exceed the speed limit. Braking time can be considerably longer when a vehicle is tow-
ing a loaded trailer. Excess speed is a major cause of vehicle-trailer accidents.
• Do not overload trailer. Overloading has adverse effects on handling, stopping, and on tires, and may cause
property damage, serious personal injury, or death.
• Make sure the coupler is secured properly to the hitch ball. If not secured properly, the ball could come
loose while the trailer is in motion, possibly causing property damage, serious personal injury, or death.
• Tighten wheel lug nuts. Failure to properly tighten wheel lug nuts and to check for proper tightness during
travel my result in property damage or serious personal injury.
2" Ball
Only -
Not Included
Locking Handle
(Position A)
Locking Handle
(Position B)
2"
Trailer
Channel
Adjustment Nut
Inspection, Maintenance, and Cleaning
All replacement parts, maintenance and repairs should be undertaken by certied and licensed technicians. The buyer
assumes all risk and liability arising out of his or her repairs to the original product or replacement parts, or arising out of
his or her installation of replacement parts.
• Once a year or every 6,000 miles, inspect the bearings for proper lubrication. Repack if necessary. Be sure to
have a qualied technician re-pack the hub assembly and handle other maintenance items.
• To reduce friction between the coupler and hitch ball, apply a layer of heavy weight grease over the hitch ball.
Lubrication of the coupler should be done periodically to stop corrosion and keep parts moving freely.
• When servicing, use only identical replacement parts. Only use accessories intended for use with this product.
Approved accessories are available from Let’s Go Aero.
• Any modications made to the trailer or parts of the trailer will void the trailer warranty and release Let’s Go Aero
of any responsibility for damages, injuries, or accidents incurred.
Steps for Determining Correct Load Limit
(1) Locate the statement “The weight of cargo should never exceed XXX kg or XXX lbs” on your vehicle’s placard.
(2) This gure equals the available amount of cargo and luggage load capacity.
(3) Determine the combined weight of luggage and cargo being loaded on the vehicle. That weight may not safely
exceed the available cargo and luggage load capacity.
(4) The trailer’s empty weight is 420 lbs, combined with 1,500 lbs of payload is the 1,920 Gross Vehicle Weight Rating.
Page 3 of 21
To Make Sure That the Trailer Ball is Completely
Engaged in the Coupler Ball
Place coupler over the 2” trailer ball on your vehicle. Raise the locking handle
to allow the coupler to drop fully onto the hitch ball. Press the locking handle
down on the coupler to make sure the hitch ball is tting snugly in the cou-
pler. There should be no play between the hitch ball and the 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.
To adjust coupler to ball, raise the locking lever, push up on the channel lock
and turn nut to tighten or loosen the coupler. Proper adjustment is obtained
when coupler is as tight as possible on the ball and locking lever can still be
opened and closed.
Hitch Coupler
*Torque set to 50-75 lbs.

Wiring
• The LittleGiant Trailer has a four at-connector wire style plug. This is a common pin hole conguration for the wir-
ing of towables. Check to verify your vehicle’s wiring plug style. Should it differ, consult your local hitch installer for a
wire plug adaptor.
• Always check all lights before towing for brake, running, signal, and side marker light operation. Make sure that all
your connections are solid and that all wiring is in good condition. Should the brake, signal, or running lights not be
working, rst check that the vehicle’s lighting is operating properly.
Note: Bare, stripped or pinched wire will cause a short in the trailer, which will cause the vehicle fuse to blow. A solid
ground is required for your lights to work properly. All contacts must be to bare metal. Light covers should be
well maintained and kept clean. Be sure that your lights are always visible, not obstructed by your load.
To test vehicle wiring:
You will need a 12v light tester. Attach the wire clamp of the tester to the ground wire on the vehicle plug. Then
touch the tester pin into one of the vehicle plug contacts. Turn on the corresponding vehicle operation, i.e., run-
ning lights. This will illuminate the tester light if the vehicle wiring is correct. Follow this same procedure for the
signal and brake lights.
To test the trailer wiring:
Once you have conrmed that the vehicle trailer plug is operating properly, connect the trailer plug to your vehicle.
Proceed to test each of the lights and power leads using your 12v light tester.
Bearing Inspection / Replacement
The bearings should be inspected any time the hub is removed from the axle or at intervals as outlined in the mainte-
nance schedule shown on page 8 of this manual. The bearing cones should show no signs of excessive wear or damage
such as at spots on the rollers, broken cages, pitting, or corrosion. The bearing cups that are pressed into the hub should
also be checked for wear or damage. If the bearings do need to be replaced, follow the procedure as outlined and only
use bearings that are approved for use in the following chart.
IMPORTANT: Both the bearing cup and bearing cone should be replaced any time a bearing is replaced.
The following procedure should be used for bearing cup replacement:
1. Carefully tap the existing bearing cup out of the hub using a brass punch
2. Clean the bore area after removing the cup to ensure there are no nicks or burrs.
3. Carefully tap the new bearing cup into the hub making sure the cup is seated against the bottom of the bore.
bearinG replaCeMenT & inTerChanGe
Axle # of Spindle Inner Bearings Outer Bearings
Capacity Bolts Type Cup Cone Cup Cone
1000# - 1900# 4 or 5 Straight L45410 L45449 L45410 L45449
Rubber Torsion Axle
With The Suspension Built-In
• Durability and Reliability.
• A Soft, Quiet, No Shock Ride With
Independent Wheel Action.
• Pre-Assembled, Easy Installation.
• Load Carrying Crossmember.
• Low Maintenance.
• Eliminates Sway.
No Coil or
Leaf Springs
Needed
Page 4 of 21

Bearing Lubrication
Below is a listing of approved lubrication.
The grease used should meet the requirements as shown in the chart above. The following amounts
of grease should be used:
• 4 ounces to completely exchange the grease throughout the hub
• 1 1/2 - 3 ounces every (3) months or 1000 miles thereafter or as use requires
lubriCaTiOn SpeCifiCaTiOnS
Grease
Dropping Point 230°C (446°F) Minimum
Viscosity Index 80 Mini-
mum
Bearing Adjustment, Hub Installation, and Lubrication
Bearing adjustment is a very important part of achieving maximum bearing life and trouble-free service. Most bearing fail-
ures can be attributed to improper bearing adjustment, normally due to the bearings being adjusted too tight.
Once all of the necessary inspections have been performed and the units have been properly lubricated, the following
procedure should be used for reinstallation of the hubs:
1. Place the lubricated unit onto the same spindle from which it was removed. Make sure all of the components are
reinstalled as they were removed.
2. Place the at washer onto the spindle followed by the bend-leg washer, followed by the castle nut.
3. Finger-tighten the castle nut by hand without moving the hub.
4. Bend the legs of the bend-leg washer to the channel of the castle nut to ensure the castle nut will not back off.
5. The castle nut should be free to move with your ngers with only the bend-leg washer holding it in place and the
hub should not have noticeable movement when pulled back and forth.
6. After assembling the hub, the grease is pumped through the hub via the grease zert in the end of the grease cap,
then through the hole in the spindle to the space between the two bearings. The nal step is to reinstall the dust
cap.
Page 5 of 21

Rubber Torsion Axle Suspension
Except for periodic inspection of the fasteners used to attach the rubber torsion axle to the trailer frame and a visual
inspection of the welds, no other suspension maintenance is required. However, all maintenance regarding hubs, drums,
rotors, bearing, wheels, and tires, should be adhered to.
The torsion suspension system is a self-contained suspension
system that is housed entirely inside the axle beam. Unlike a
spring suspension system, the axle beam attaches directly to the
trailer frame without the need for various mounting components.
The action provided by the rubber torsion axle provides several
operating advantages (over leaf spring suspension) including
independent suspension for each wheel and a maintenance-free
design.
How the Rubber Torsion Suspension System Works
The rubber torsion axles provide a much improved trailer
ride relative to conventional spring axles through a unique
arrangement of the steel torsion bar surrounded by four nat-
ural rubber cords encased in the main structural member of
the axle beam. The wheel/hub spindle is attached to a lever,
called the torsion arm assembly. This assembly includes the
torsion arm, the torsion bar and spindle. As load is applied
to the trailer, the torsion arm assembly pivots around the tor-
sion bar, causing a rolling or compressive resistance in the
rubber cords inside of the axle beam. Both sides of the axle
are completely independent from one another.
Direction of Travel
The rubber torsion axle beams and stub axles must be
mounted with the torsion arm and spindle trailing to the rear
of the axle beam.
As Load is Applied to the Trailer, the Torsion
Arm Moves to Absorb the Shock
Wheels and Tires
Wheel Selection
Wheels are a critical component of your running gear system. When specifying or replacing your trailer wheels it is
important that the wheels, tires, and axle are properly matched. The following characteristics are extremely important
and should be thoroughly checked when replacement wheels are considered.
1. Bolt Circle. Many bolt circle dimensions are available and some vary by so little that it might be possible to attach
an improper wheel that does not match the hub. Be sure to match you wheel to the hub.
2. Capacity. Make sure that the wheels have enough load carrying capacity and pressure rating to match the maxi-
mum load of the tire and trailer.
3. Offset. This refers to the relationship of the centerline of the tire to the hub face of the axle. Care should be taken
to match any replacement wheel with the same offset wheel as originally equipped. Failure to match offset can
result in reducing the load carrying capacity of your axle.
Torque Requirements
It is extremely important to apply and maintain proper wheel mounting torque on your trailer axle. Torque wrenches
are the best method to ensure the proper amount of torque is being applied to a fastener.
It is important that the specied torque levels are maintained on the wheel nuts or bolts on your axle to prevent loose
wheels, broken wheel studs, and possible wheel separation from the axle.
Wheel nuts and bolts are offered in different cone angles (usually 60° or 90°). It is important to match the angle of the
fastener to the wheel on the axle.
Page 6 of 21

1
2 3
4 5
5 Bolt Pattern
Wheel TOrque valueS
Wheel Size 1st Stage 2nd Stage 2nd Stage
13" 20-25 ft./lbs. 35-40 ft./lbs. *50-75 ft./lbs.
Tires
Like the tires on a car, the most important factor in the life of the tires on your trailer is their ination pressure. The recom-
mended tire ination pressure is 30 PSI. Underinaton of tires will lead to added wear and tear and tire failure. During use
of your trailer, ination pressure should be checked weekly and performed when the tires are cold (prior to operation of the
trailer). In doing this, you will ensure that you are achieving the maximum life and tread wear for your tires.
The proper procedure for the attachment of your wheels is listed at right.
1. Start all bolts or nuts by hand to prevent cross threading.
2. The tightening of the fasteners should be done in stages. Following the
recommended sequence (illustration, right), tighten fasteners per the wheel torque
chart below.
3. Wheel fasteners should be torqued before the rst initial road usage and
after each wheel removal. Check and retorque the wheel fasteners after the rst 50 miles and again at 500 mile
intervals. Check periodically thereafter to ensure that the proper torque values are maintained.
Wheels and Tires – Inspection and Maintenance
Wheels should be visually checked periodically for dents or cracks. Whenever it is required to have a tire replaced on a
rim, the wheel needs to be checked for balance and distortion.
Tire wear should also be checked often for abnormal or excessive wear. The following chart will aid you in troubleshooting
if abnormal or excessive tire wear should occur. It is important to monitor tire wear, as once a wear pattern becomes rmly
established in a tire it is difcult to stop, even if the underlying cause is corrected.
Tire Wear diaGnOSTiC CharT
Wear Pattern Cause Action
Center Wear Overinated tire Adjust tire pressure to specic load rating per tire catalog
Edge Wear Underinated tire Adjust tire pressure to specic load rating per tire catalog
Side Wear Loss of camber Make sure load does not exceed axle rating. Realign axle
or overloading at axle shop
Toe Wear Incorrect toe-in Align at alignment shop
Cupping Out-of-balance Check bearing adjustment and balance tires
Flat Spots Wheel lockup Avoid sudden stops when possible and adjust brakes
and tire skidding
Page 7 of 21

Maintenance Schedule
Below is a maintenance schedule for routine maintenance of your trailer.
Item Function 500 Mile 3 Months 6 Months 12 Months Refer to
Required Intervals or or or Page
1000 Miles 3000 Miles 6000 Miles
Hub/Drum/Rotor Inspect for
abnormal wear • ––
Bearings (Sure Lube- Replenish grease
Bearing Lube) in the system •4
Seals Inspect for leakage
Replace if worn •––
Wheel Lug Nuts and Bolts Check torque
values •6
Page 8 of 21

parTS idenTifiCaTiOn
Parts List Overview
Item Description
A Floor and Sidewall Trailer Body Panels
B 5 x 4.5 Lug Pattern Torsion Axle with
Autolube Fitting
C Fenders
D 2" A-Frame Coupler
E Safety Cables
F 84" x 1.625" C-Channels
G 56" x 23" U-Tubes
H 84" x 2" x 2" Frame Tubes
I 55" x 2" x 2" A-Frame Tubes
J 2" x 2" x 48" Frame Angle
K 13" Tire & Wheel Assembly ST 175/80D13
Tire & Wheels
L Stud Mount Passenger Tail Light
without License Illuminator
M Stud mount Driver Tail Light
with License Illuminator
N Amber Lights, Front Marker Light
O L-Bend Bolt On Light Brackets
P License Plate Triangular Plate
Q 4-Flat Wire Lighting Harness with
Four-Flat Connector
R End Gates
S 5/16” Snap Pins
T 1-1/2" Wide End Gate Support L-Brackets
(Fits Inside Trailer Frame Tube)
U 1" Wide Steel Angle End Gate Latch
(Fits Trailer Body)
V 2" Wide Steel Angle Body Latch
(Fits End Gates)
W Self Drilling Screws
X&Y Spring Nut, L-Bracket, Hardware Kit:
Front
X 5/16” Spring Nuts, 1/2” Spring Nut with 5/16” X 2”
Bolts, 1/2” X 1” Bolts, Spring Nut Holder
and Washers
Rear
Y 5/16” Spring Nuts with 5/16” X 2” Bolts, Washers,
Split Ring Lock Washers
End Gate Support L Bracket
A
A
S
A
A
C
M
D
F
F
H
H
E
C
B
G
Q
J K
K
T
I
X & Y
X & Y
RR
I
R
R
U
Z
AA
W
RR
LL
CC
Y
BB
V
MM
T
Page 9 of 21

hardWare idenTifiCaTiOn
Hardware List Overview
Item Description
AA 1/2” x 3” Bolts
BB 1/2” Flat Washers
CC 1/2” Nylon Lock Nuts
DD 5/16” x 1-3/4” Bolts
EE 5/16” x 4” Bolts
FF 5/16” Washers
GG 5/16” Lock Nuts
HH 5/16” Split Ring Lock Washers
II Wire Pad Holder with Adhesive
JJ 5/16” Spring Nuts
KK 1/2” Spring Nuts
LL 5/16” x 2” Bolts
MM 1/2” x 1” Bolts
NN Spring Nut Holder
OO Safety Cable Washers
PP 5/16” x 1” Bolts
QQ Pin Nut
RR 5/16” Internal Tooth Lock Washer
SS 1/2” Lock Washer
TT Star Washers
UU 1/4” Flat Washer
VV 1” Flat Washer
WW 1/2” x 3” Bolt
XX 1” Endgate Support Bracket
YY 2” Endgate Body Latch
ZZ 1/4” x 1” Flat Washer
Page 10 of 21

Tools Needed
1/2” Socket Wrench
3/4” Socket Wrench
3/4” Box Wrench
1/2”Box Wrench
Lug Wrench
Phillips head and 3/8” Hex Nut Driver
#2 Phillips Screwdriver Bit
Wire Stripper
Drill for Self Drilling Screw
Description Quantity
Step 12
(DD) 5/16” x 1-3/4” Bolt 8
(UU) 1/4” Flat Washer 16
(GG) 5/16” Lock Nut 8
(XX) 1” Endgate Support Bracket 4
Step 13
(DD) 5/16” x 1-3/4” Bolt 8
(UU) 1/4” Flat Washer 8
(GG) 5/16” Lock Nut 8
(YY) 2” Endgate Body Latch 4
Foam Roll 2
Step 14
(S) Snap Pin 4
Step 15
Wire Harness (in Light Box) 1
Nylon Zipties (in Light Box) 6
Step 16
S/T/T Tail Lights Passenger Side (in Light Box) 1
S/T/T Tail Lights Driver Side (in Light Box) 1
Light Bracket 2
(DD) 5/16” x 1-3/4” Bolt 4
(FF) 5/16” Flat Washer 8
(GG) 5/16” Lock Nut 4
Butt Connectors 10
Step 17
Side Marker Light Assembly 2
(Located in Light Box)
Step 18
1” Spacer 8
5/16- 18x2” Carriage Bolt 8
5/16 Lock Nut 8
5/16 Flat Washer 8
Step 19
10 X 3/4” Machine head screws 2
(VV) 1” Washers 4
Nylocks 2
Step 2
(AA) 1/2” X 3” Bolt 4
(AA) 1/2” Flat Washers 8
(CC) 1/2” Nylon Lock Nuts 4
Step 3
Spring Nut, L-Bracket, Hardware:
(JJ) 5/16” Spring Nut 2
(KK) 1/2” Spring Nut 2
(MM) 1/2” X 1” Bolt 2
(JJ) 1/2”Lock Washer 2
(BB) 1/2” Flat Washer 2
(LL) 5/16” X 2” Bolt 2
(FF) 5/16” Flat washer 2
(HH) 5/16” Split ring lock washer 2
(OO) Endgate L-Bracket 2
(NN) Spring Nut Holder 4
Step 4
(AA) 1/2” X 3” Bolt 4
(CC) 1/2” Lock Nut 4
(BB) 1/2” Flat Washer 8
Step 5
(WW) 1/2” X 3-1/2” Bolt 2
(AA) 1/2” X 3” Bolt 2
(CC) 1/2” Lock Nut 4
(BB) 1/2” Flat Washer 8
(E) Safety Cables 3/4” X 2” 2
(PP)Safety Cable Washers (Big) 2
Step 7
(EE) 5/16” X 4” Bolt 12
(FF) 5/16” Flat Washer 28
(GG) 5/16” Lock Nut 14
(LL) 5/16” x 2” Bolt 2
Step 8
(QQ) 5/16” x 1” Bolt 16
(FF) 5/16” Flat Washer 16
(RR) Pin Nut 16
(SS) 5/16” Internal Tooth lock washer 16
(T) Endgate Support L-Bracket 2
Step 10
(W) Self Drilling Screw 12
(VV) 1” Flat Washer 12
(TT) Star Washer 12
Step 11
(W) Self Drilling Screw 22
(VV) 1” Flat Washer 22
(TT) Star Washer 22
For ease of assembly, small hardware parts are kitted and marked by assembly step. Below is a description of parts and quantities:
(Extra hardware Provided for smaller fasteners and screws)
Description Quantity
Page 11 of 21

1. Unpack Crate for Assembly
Remove the trailer parts from the crate. Remove
the 2 - 84” steel trailer body panels, 2 - 84” Side
Panels with corner coves and the 84” C-Channels.
liTTleGianT Trailer™ aSSeMbly
Important Notice on Assembly Tightening of Trailer’s Under Carriage:
The LittleGiant Trailer (LGT) is a precision built product and some consideration of “alignment” is necessary when rst
assembling the trailer’s under carriage. The LGT uses “symmetry” in a balanced manner, so when bolting the under
carriage together for the rst time, tighten all hardware in a two step process. First, tighten the trailer frame assembly to
set the components in position, referred to as “Assembly Fit”. Final Tightening occurs at Step 9. Final Tightening of 5/16”
bolts should be to 15 foot lbs of torque. Final Tightening of 1/2” bolts should be to 30 foot lbs of torque.
2. Attach Frame Tubes to Axle
Locate the Torsion Axle (B) and the two Trailer Frame Tubes (H) in the parts kit.
Place the Trailer Frame Tubes over the mounting brackets on the axle and line up the holes in the tubes with the
holes in the brackets.
Secure the tubes to the axle with four (4) 1/2” x 3” Bolts (AA), eight (8) 1/2” Flat Washers (BB) and four (4) 1/2”
Nylon Lock Nuts (CC). Tighten the hardware for “Assembly Fit”, but wait until later in the assembly process
to “Final Tighten” this hardware.
Front
1/2” Hole
1/2” X 3” Bolts
(BB)
Torsion
Axle (B)
Trailer Frame
Tube (H) 1/2” X 3”
Bolts (AA)
1/2” Nylon
Lock Nuts
(CC)
1/2” Flat
Washers
(BB)
1/2” Flat
Washers
(EE)
1/2” Nylon Lock
Nuts (CC)
Rear
1/2” Hole
2
3
5
6
4
12
11
10
9
Page 12 of 21

4. A-Frame Tubes & Wiring
Locate the two (2) A-Frame Tubes (I), the 4-Flat Wire Lighting Harness (Q), four (4) 1/2” X 3” Bolts (AA), four (4) 1/2”
Nylon Lock Nuts (CC) and eight (8) 1/2” Flat Washers (BB) in the parts kit.
3. Install Endgate Support Brackets
Locate the Frame Angle (J), Step 3 Hardware Kit , and
the two (2) End Gate Support L-Brackets (T).
Start from the front (hitch side) of the trailer and position
a 5/16” Spring Nut (JJ) and a 1/2” Spring Nut (KK) as
shown. Place the Spring Nut Holder (NN) at the top and
bottom of the Spring Nut assembly as shown. Slide the
assembly inside the end of each Trailer Frame Tube
with the 5/16” Spring Nut facing up and an End Gate
L-Bracket (T) inserted between the 5/16” Spring Nut
and the top of the frame tube.
Attach the Frame Angle (J) to the bottom of each frame
tube with a 1/2” X 1 Bolt, 1/2” Lock Washer and 1/2”
Flat Washer. Tighten this hardware for “Assembly Fit”
(Final tighten later).
Insert the 5/16” X 2” Bolts and 5/16” Lock Washers
through the top of the Frame Tubes to hold the Spring
Nuts in place.
Wiring:
Slide the driver and passenger wire harness lengths through the A-Frame tubes with the solid yellow lead
on the driver side and the solid green lead on the passenger side.
Mount the A-Frame Tubes under the LGT frame assembly using the sets of 1/2” hardware as shown. Tighten these
four (4) hardware sets for Assembly Fit.
Trailer Frame
Tubes
Frame
Angle (J)
End Gate Support
L-Bracket (T)
5/16” Spring
Nut (JJ)
1/2” Spring
Nut (KK)
1/2” X 1 Bolts, 1/2” Lock
Washers and 1/2” Flat
Washers (MM, TT, BB)
5/16” X 2” Bolt
& 5/16” Lock
Washer (LL &
HH)
5/16” X 2” Bolt &
5/16” Lock Washer
(LL & HH)
Spring Nut
Holder (NN)
1/2” Flat Washers
(BB) and 1/2” Lock
Nuts (CC)
A-Frame
Tubes (I)
1/2” X 3” Bolts
(AA) and 1/2”
Flat Washers
(BB)
Yellow
Lead
Green Lead
1/2” X 3” Bolts
(BB) and 1/2” Flat
Washers (BB)
4-Flat Wire
Lighting Harness
with Four-Flat
Connector (Q)
Warning Labels Must Be
on Drivers Side facing
outward
Page 13 of 21

6. Install Wheels
Install the wheels on the axle. Tighten the lug nuts to 50 to 75 foot pounds. Refer to the Wheels and Tires Section
of this manual. After using the trailer for 50 miles, re-check the lug nuts to insure they have remained tight.
Tighten Lug Nuts
to 50 – 75 ft. lbs
5. Install A-frame Coupler and Safety Cables
Locate the A-Frame Coupler (D), the two (2) Safety Cables (E), two 1/2” X 3” Bolts (AA), two (2) 1/2” X 3-1/2” Bolts,
four (4) 1/2” Nylon Lock Nuts (CC) and six (6) 1/2” Flat Washers (BB), and two (2) 1/2” Bigger Flat Washers for
Safety Cable area as noted below.
Attach the A-Frame Coupler (D) to one of the A-Frame tubes and install the Safety Cable in the front hole of the
coupler. Install two 1/2” X 3” Bolt, two 1/2” Nylon Lock Nut and four 1/2” Flat Washers on of the coupler to attach it
to the A-Frame Tube. Using two 1/2” X 3-1/2” Bolt, two 1/2” Nylon Lock Nut, two 1/2” Flat Washers and two bigger
washer install safety cable on the coupler Tighten this hardware for Assembly Fit (Tighten later).
4-Flat Wire Lighting Harness
with Four-Flat Connector
A-Frame
Coupler (D)
Safety Cable (E)
1/2” Flat
Washer
(BB)
1/2” Flat
Washer (BB)
Bigger Washer
1/2” X 3” Bolt
1/2” X 3”
Bolt (AA)
1/2” Flat
Washer (BB)
1/2” X 3-1/2” Bolt
Page 14 of 21

7. Install U-Tubes
Locate the U-Tubes, two (2) 5/16” X 2” Bolt assemblies (LL), twelve (12) 5/16” X 4” Bolt assemblies (EE), sixteen
(16) 5/16” X 1” Bolts (QQ),and sixteen (16) 5/16” Flat washers (FF).
Two U-Tubes are unique from the other six. These two have custom holes that are meant to be secured at
the front (3 holes) and the rear (5 holes) of the trailer. The remaining U-Tubes are all identical and can be
used in any order.
Remove the bolts in the front holes (nearest to the hitch) in the Frame Tubes. Place U-Tube with (3-Holes) over these
holes and secure it with the bolts (used in step 3.) Place U-Tube with (5-Holes) over the rear holes and use the two
(2) 5/16” X 1-3/4” Bolts (DD) to hold it to the Frame Tubes.
Use the twelve (12) 5/16” X 4” Bolts (EE) and use the bolts to hold the remaining U-Tubes to the Frame Tubes. Do
not install the washers and lock nuts at this time.
Important: All bolts will t properly if the undercarriage is square. The undercarriage has a loose t to allow for adjustment
at this stage if it is necessary.
5/16” X 1” Bolts,
Stainless Steel Flat
Washers, SS Split Ring
Washers (X) 5/16” X 2”
Bolts (DD) with
Washers &
Lock Nuts
5/16” X 4”
Bolts (EE) with
Washers &
Lock Nuts
8. Install Side Panels and Floor Panels
Once the U-Tubes are mounted on the Frame Assembly in the proper order, place a Pin Nut into the openings in the
top of each U-Tube. Align the slot in the Pin Nut with the side of the U-Tube so that the side of the tube will go into
the nut when it is tightened. If necessary, lightly tap the Pin Nut into place with a plastic hammer to avoid damaging
the Pin Nut.
Locate the 84” x 20” side panels and position the 1” panel return on top of the U-Tubes, with the 20” portion of panel
resting on the inside of the U-Tubes.
Place the two C-Channels on top of U-Tubes/panel prole and install the sixteen (16) bolts and hardware from the
Pin Nut assemblies (5/16” X 1” Bolts, Stainless Steel Flat Washers, Lock Washers). Thread the bolts through the
C-Channels, side panels and into the Pin Nuts.
Secure all hardware for Assembly Fit (Tighten later).
Page 15 of 21
IMPORTANT:
Correct placement of side panels means 4 square
holes (fender mount holes) will be above axle.

Locate the 24" x 84" Floor Panels, two (2) remaining 1-1/2" Wide End Gate Support L-Brackets (T).
Remove the 5/16” x4” Bolts (EE) that secure the eight U-Tubes to the Frame Tubes on one side. Place one of the
24" x 84" Floor Panels on top of the U-Tubes. Place a 1-1/2" Wide End Gate Support L-Bracket into the rear ends
of the Frame Tubes. Reinstall the bolts, starting with the 3-hole U-Tube to secure the Floor, Support L-Bracket and
U-Tube to the Frame Tube. Then reinstall the 5/16” X 2” Bolt (DD) in the 5-hole U-Tube using the 5/16” Washers on
the top and the 5/16” Flat Washers and Lock Nut on the bottom to secure the Floor, Support L-Bracket and U-Tube
to the Frame Tube.
Once the 3-hole and 5-hole U-Tubes are secure, reinstall the 5/16” X 4” Bolts, Washers, and Lock Nuts (EE) in the
same manner.
Important: Make sure that the oor panels are square with U-Tubes 1 and 8 before setting screws. Adjust the
undercarriage if necessary.
Tighten the bolts for Assembly Fit. Repeat this on the other side of the trailer.
5/16” X 4” Bolts
(EE) with Flat
Washers & Lock
Nuts
5/16” X 2”
Bolts (LL) with
Washers &
Lock Nuts
1-1/2" Wide
End Gate
Support
L-Bracket (T)
9. Tighten Bolts
Once all the U-Tube/Floor mounting bolts are installed and assembly tightened, tighten these bolts to a nal torque of
15 foot pounds.
Final Tighten the remaining hardware on the trailer frame, torsion axle and coupler. Final tightening of 5/16”
bolts should be to 15 foot lbs of torque, and to 30 foot lbs of torque for the 1/2” bolts.
Page 16 of 21

11. Secure Side Panels
Use the pre-drilled holes on the side panel where
it starts to curve as a guide. Install sixteen (16)
Self Drilling Screws (W) with sixteen (16) Star
Washers and sixteen (16) Flat Washers to secure
the side panels to the U-Tubes. For best results
apply only a little pressure when installing the
screws. Repeat on opposite side.
10. Install Body Fasteners
Locate the twelve (12) Self Drilling Screws (W), twelve (12) 1” Flat Washers (VV) and twelve (12) Star Washers.
Use the pre-drilled holes in the center of the oor panels and at front and rear center of panel locations as a guide to
engage and tighten the self drilling fasteners though the oor panels and into the U-Tubes with an electric drill and a
Phillips head.
12. Install Side Body Latches
Use the holes in the outside of the front and rear
U-Tubes as guides to install 1" End Gate Latch (U) in
these holes on the outside of the U-Tubes using eight
(8) 5/16” x 1-3/4” Bolts (DD), 1/4” Flat Washers (UU),
and 5/16” Lock Nuts (GG).
1" End Gate
Support Bracket (U)
1/4” Flat Washers
& 5/16” Lock Nuts
(VV, GG)
5/16” x 1-3/4” Bolt
(DD)
Self Drilling Screws used
to secure side panels
Page 17 of 21

14. Insert Snap Pins
Insert the Snap Pins (S) into the End Gate
Latch Angles.
If the pins are too tight and a looser t is
desired drill out the hole in the endgate latches.
13. Install Endgate Side Latch & Position Endgate
Locate the two (2) Foam Roll, 2" End Gate Latch Angles (V), eight (8) 5/16” x
2” Bolts (LL), eight (8) 5/16” Lock Nuts (GG), eight (8) 1/4” Flat Washers (UU)
and the four (4) Snap Pins (S).
Clean surface of End Gates with rubbing alcohol prior to installing foam. Install
Foam on the inside edge of the End Gate.
Loosely install the End Gate Latches as shown. Use the Snap Pins to check
the alignment of the latches. Once the latches are aligned properly, tighten the
hardware.
15.Wiring: Routing and Connections
Make sure that the solid yellow lead is on the driver’s
side and the solid green lead is on the passenger side
per Step 4.
Where the wire harness exits the A-Frame, weave the
loose ends of the wire harness in and out of the U-Tubes
to the rear of the trailer. The plastic ties may be utilitized.
Snap Pins
o
lidWorks Student License
c
ademic Use Only
2" End Gate
Latch Angle 5/16” x 1-3/4” Bolts (outside)
1/4” Flat Washer
& Lock Nut (inside)
2" End Gate
Latch Angle
1" Body Latch Rear End
Gate
Use Snap Pin to
align brackets
Place Foam on the inside edge
of the End Gate.
Page 18 of 21

16. Light Kit Installation
17. Install Side Marker Lights
The left and right Amber Front Side Marker Lights plug into the wire harness. Each marker light has two plugs,
which are interchangeable. Locate the corresponding plugs on the Wire Harness, and route the Light along with the
Wire Harness through the A-Frame Tube. Using two self tapping screws*, attach each side marker light base to the
main frame tube. Then, press the light onto the base.
Self Drilling
Screws
Crimps
Front Side
Marker Light
Page 19 of 21
CONNECTOR
Attach tail lights to tail light brackets.
NOTE: Tail light with GREEN WIRE
on the curb side of the trailer.
IMPORTANT: Take care tightening
each nut only so far as to compress
the lock washer, then STOP.
Join three wires, matching like colors,
with connectors provided. Use a wire
crimper as detailed below (remove .5”
of wire sheathing from end of each
wire if not already done). Cover the
three wires with convolute provided.
Attach tail light brackets to back
corners of trailer.
JOIN CRIMP COVER

18. Install Fenders
19. License Plate Installation
Using the existing holes in the Light bracket mount the license plate using hardware provided in Step 19 as shown
in the driver’s side of the trailer.
Page 20 of 21
Attach each fender as shown using 4 carriage bolts, 1” spacers, fender washers and lock nuts.