Malone MPG460XT User manual
MPG460XT
MALONE
R
MALONE
R
*ATTENTION CUSTOMERS*
Thank you for your recent purchase of a Malone trailer.
Please inspect all parts and hardware bags prior to assembly.
**Set the large red envelope (in the axle box) containing important
documents pertaining to registering your trailer in a safe spot.
If you encounter any missing components please contact us at:
Email:[email protected]
OR
Phone:(207) 774 - 9100 X215
Business Hours: Monday-Friday
9am- 5pm
Thank you from all of us at Malone
Important Note
Product Warranty & Registration Form
All information is condential and used exclusively by MALONE only.
MALONE
R
Dear Customer,
Thank you for your purchase of a Malone Product.
In order to be eligible for the Malone Warranty program, we ask that you contact us by email or
online at one of the following: With-in 30 days of purchase. You can also mail this letter back to the address at
the bottom.
• Online: www.maloneautoracks.com
We will require the information below.
Here is the information collected:
First Name:
Last Name:
Address:
Address2:
City:
State:
Zip:
Country:
Email:
Phone:
Product Description/Name:
Product MPG# or Serial #
Date Purchased:
Store Where Purchased:
Purchase Price:
Thank you for choosing Malone!
81 County Rd. Ste 1, Westbrook, ME 04092
P: 207.774.9100 F: 207.615.0551
E: sales@maloneautoracks.com W: www.maloneautoracks.com
800-295-0042 ext 206
MPG460XT
Take a few moments and read through these instructions to familiarize yourself
with the step by step assembly process before you begin turning wrenches.
Unpack and sort the components into groups as shown in the following pages.
Then assemble each group in order. Lets get started !!
Required Tools:
• (2) 3/4” wrenches • (2) 9/16” wrenches (a deep socket is recommended)
• Large flat blade screw driver • (1) 7/16” wrench
• Razor knife • Pliers
• Wire stripping tool • Electrical connector crimping tool
• Lug wrench • Small hammer
Visit us at maloneautoracks.com
for more fine products and accessories.
Malone MicroSport Trailer
Model MPG460XT Assembly Instructions
TM
REV 2
MPG460XT
Malone MicroSportTM Trailer
Model MPG460XT Assembly Instructions
Take a few moments and read through these instructions to familiarize yourself with the
step by step assembly process before you begin turning wrenches.
Unpack and sort the components into groups as shown in the following pages.
Then assemble each group in order. Lets get started !!
Required Tools:
• (2) 3/4” wrenches • (2) 9/16” wrenches (a deep socket is recommended)
• Large at blade screw driver • 7/16” wrench • 3/8” wrench and socket
• Large Phillips head screw driver • Rubber hammer
MALONE
R
MALONE
R
800-295-0042 ext. 215 1
Bag 11491
MPG460XT
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2
Group 1:
Frame
Components
Bag 11462
Group 2:
Axle / Spring
Components
Bag 11476
11429
NOTE: actual aluminum wheel may vary from
images
Visit www.maloneautoracks.com/Replacement-Parts
for all of your spare part needs
800-295-0042 ext 206
MPG460XT
Group 4:
Fender Components Bag 11464
Group 3: Lighting Components Bag 11468
Group 5: Coupler Components
Bag 11494
L.E.D. REFERENCE:
Trailer Wiring Color Code
•Brown = running lights
•Yellow = left turn / left brake
•Green = right turn / right brake
•White = ground
Group 3: Lighting Components
Bag 11468
Group 5: Coupler Components
Bag 11494
Visit www.maloneautoracks.com/Replacement-Parts
for all of your spare part needs
MPG460XT
800-295-0042 ext 206
4
FRAME ASSEMBLY (Group 1)
1. We assemble the frame upside down to make it easier to install the springs
and axle. Once the spring and axle assembly is installed we will flip the trailer
over to complete the assembly. So first, layout the frame components upside
down as shown. The spring bracket mounting holes should be facing up. All
the decals should all be upside down.
Bag 11489
Group 6:
Load Bar
Components
MPG460XT
800-295-0042 ext 206
4
FRAME ASSEMBLY (Group 1)
1. We assemble the frame upside down to make it easier to install the springs
and axle. Once the spring and axle assembly is installed we will flip the trailer
over to complete the assembly. So first, layout the frame components upside
down as shown. The spring bracket mounting holes should be facing up. All
the decals should all be upside down.
Bag 11489
Group 6:
Load Bar
Components
MPG460XT
800-295-0042 ext 206
4
FRAME ASSEMBLY (Group 1)
1. We assemble the frame upside down to make it easier to install the springs
and axle. Once the spring and axle assembly is installed we will flip the trailer
over to complete the assembly. So first, layout the frame components upside
down as shown. The spring bracket mounting holes should be facing up. All
the decals should all be upside down.
Bag 11489
Group 6:
Load Bar
Components
X4
Visit www.maloneautoracks.com/Replacement-Parts
for all of your spare part needs
800-295-0042 ext 206
MPG460XT
2. Attach the spring hanger brackets to the frame. The U
shaped shackle bolt brackets mount to the front and the
C shaped “slipper” brackets mount to the rear as shown.
Use 3/8” x 1” bolts and nuts. Assemble with the nuts on
the inside of the
frame rails. Fully
tighten all 8 bolts
now.
3. Lay the two frame cross members
in between the frame rails. The
two holes in the middle should face
DOWN as shown. Channels face
each other.
4. Bolt the frame rails to the cross members
using 3/8” x 1” carriage bolts and nuts, (no
washers). The square carriage heads go to
the outside with the square holes in the frame
rails.
Leave the nuts loose until after all bolts are
installed. You will tighten everything at once in
a later step.
technical@maloneautoracks.com
800-295-0042 ext.215
3. Lay the two frame cross members
in between the frame rails. The large
Malone decal should be in the rear,
facing upside down.
MPG460XT
800-295-0042 ext 206
6
5. Slide the clip nut onto
the hole in the top of the
short tongue. Note, these
two parts are symetrical
so it doesn’t matter which
way they are turned. Slide
the short tongue inside the
tongue support and install a
bolt and washer hand tight
only. Flip the assembly over
so the bolt is on the bottom.
6. Set the assembly inside the
frame and slide it forward in
between the frame rails until the
holes all come into alignment.
7. Push the retractable tongue box onto the frame and slide it rearward to engage its notch inside
the tongue support. Install 1/2” bolts with washers on both sides, the forward 1/2” bolt getting a
crush preventer tube inside the short tongue.
Hand tight both 1/2” bolts with washers on
both sides.
technical@maloneautoracks.com
800-295-0042 ext.215
800-295-0042 ext 206
MPG460XT
8. Bolt the tongue support to the frame
rails using 3/8” x 1” carriage head bolts.
Assemble with washers and nuts on the
inside. Don’t fully tighten.
9. FRAME BOLT TIGHTENING: Starting at the rear of the frame fully tighten each
bolt, working to the front, fully tighten all frame bolts ending with the 1/2” bolts.
You don’t have easy access to tighten the rear tongue support bolt until after you flip
the trailer over.
technical@maloneautoracks.com
800-295-0042 ext.215
MPG460XT
800-295-0042 ext 206
8
SPRING AND AXLE ASSEMBLY
(Group 2)
2. Spin the axle to find the side with the spring
centering holes. These holes mate with the spring
center stud (shown to the left)
1. Set the envelope containing the manufacturer’s
certificate of origin (MCO) and VIN labels aside in a safe
place.
technical@maloneautoracks.com
800-295-0042 ext.215
NOTE: actual aluminum wheel may vary from
images
800-295-0042 ext 206
MPG460XT
4. Run each nut down but,
ONLY UNTIL THE NUTS
ALMOST TOUCH
THE PLATE !!
You will need lots of wiggle in
the springs to fit them into the
spring brackets in the next step.
5. Lift the axle/spring assembly to the trailer frame and slide the slipper spring
ends into the slipper spring brackets as shown. Then lower the axle resting the
spring eyes on the front brackets however they land.
technical@maloneautoracks.com
800-295-0042 ext.215
MPG460XT
800-295-0042 ext 206
10
6. Wiggle the spring eyes into the front hanger
brackets and bolt using 1/2” x 3” bolts and self
locking nuts. Nuts to the inside. Tighten the
shackle bolts ONLY until they grip the sides of the
brackets. Remember, this is a hinge. The bolt
should remain still in the bracket allowing the spring
eye to move freely.
8. Slip the hub caps through the wheels
from the back then mount the wheels onto
the hubs. Hand tighten the lug nuts.
7. Now that the axle assembly is attached
to the frame, tighten the axle plate U-bolts
evenly until there is a slight bend in the tie
plates. Don’t over tighten.
9. Grasp the front of the trailer, lift with your
knees and step around the trailer
when it balances on the rear of
the frame, then let it down onto
the tires.
ALWAYS BEND FROM YOUR
KNEES WHEN LIFTING.
IF THE TRAILER IS TOO HEAVY
FOR YOU TO LIFT SAFELY,
STOP, GET SOME FRIENDS TO
ASSIST YOU.
technical@maloneautoracks.com
800-295-0042 ext.215
800-295-0042 ext 206
MPG460XT
10. Tighten the lug firmly
to 75 to 85 foot pounds of
torque.
13. Fully tighten the bolt in the top
of the tongue support
12. Install the 2” x 3” plastic
hole plug into the end of the
frame as shown. Use your
hammer to tap it in.
technical@maloneautoracks.com
800-295-0042 ext.215
10. Tighten the lug nuts rmly to 75 - 85
foot pounds of torque.
800-295-0042 ext 206
MPG460XT
10. Tighten the lug firmly
to 75 to 85 foot pounds of
torque.
13. Fully tighten the bolt in the top
of the tongue support
12. Install the 2” x 3” plastic
hole plug into the end of the
frame as shown. Use your
hammer to tap it in.
11. Install the tube end plug into the open
end of the short tongue tube.
800-295-0042 ext 206
MPG460XT
10. Tighten the lug firmly
to 75 to 85 foot pounds of
torque.
13. Fully tighten the bolt in the top
of the tongue support
12. Install the 2” x 3” plastic
hole plug into the end of the
frame as shown. Use your
hammer to tap it in.
12. Loosen the 1/2” bolts and Slide the
u-shaped spacer between the short tongue
tube (one on each side) and the frame rail
as shown. Now Fully tighten the 1/2” lock
nuts. Be careful not to crush the frame!
NOTE: This spacer insures the tongue will
slide freely.
MPG460XT
800-295-0042 ext 206
12
15. Install the wiring harness extension
through the tongue.
The easiest way is to let gravity pull the
harness through. Make a fold in the
harness near the end with the white
ground wire. Push the fold into a heavy
socket (or tape any heavy object to the
fold). Feed the weight into the tongue and
let gravity pull the harness through. Remove the weight.
13. Attach the two rubber stand-up
feet to the rear of the frame. Tighten
until snug only.
14. Cut two slits for the bolts to pass through the
decal. Attach the retractable tongue retainer bracket
to the inside of the rear frame crossmember with a
washer under the bolt head.
16. Slide the rear end of the tongue into the retractable receiver box until the pin hole in the box
aligns with one of the 2 pin holes in the sides of the tongue. Pass the hitch pin through and install
the ring clip.
technical@maloneautoracks.com
800-295-0042 ext.215
16. Identify the hitch end of the tongue by the 3 holes on
the left (drivers) side and Install the wiring harness exten-
sion (with a plug at each end),through the tongue, leaving
enough excess at the front to reach the vehicle. NOTE:
MAKE SURE YOUR PLUG MATCHES THE VEHICLE
CONNECTION. IF NOT REVERSE YOUR WIRING
HARNESS NOW.
15. Mount the tongue slide stop to the inside center of the rear
cross member. Nuts on the inside, bolts and washers on the
outside.
14. Attach the two rubber stand-up feet to the
rear of the frame. Tighten until snug only
17. Slide the rear end of the tongue into the retractable receiver box until the pin in the box aligns
with one of the 2 pin holes in the side of the tongue. Pass the hitch pin through and install the ring
clip.
MPG460XT
800-295-0042 ext 206
12
15. Install the wiring harness extension
through the tongue.
The easiest way is to let gravity pull the
harness through. Make a fold in the
harness near the end with the white
ground wire. Push the fold into a heavy
socket (or tape any heavy object to the
fold). Feed the weight into the tongue and
let gravity pull the harness through. Remove the weight.
13. Attach the two rubber stand-up
feet to the rear of the frame. Tighten
until snug only.
14. Cut two slits for the bolts to pass through the
decal. Attach the retractable tongue retainer bracket
to the inside of the rear frame crossmember with a
washer under the bolt head.
16. Slide the rear end of the tongue into the retractable receiver box until the pin hole in the box
aligns with one of the 2 pin holes in the sides of the tongue. Pass the hitch pin through and install
the ring clip.
MPG460XT
800-295-0042 ext 206
12
15. Install the wiring harness extension
through the tongue.
The easiest way is to let gravity pull the
harness through. Make a fold in the
harness near the end with the white
ground wire. Push the fold into a heavy
socket (or tape any heavy object to the
fold). Feed the weight into the tongue and
let gravity pull the harness through. Remove the weight.
13. Attach the two rubber stand-up
feet to the rear of the frame. Tighten
until snug only.
14. Cut two slits for the bolts to pass through the
decal. Attach the retractable tongue retainer bracket
to the inside of the rear frame crossmember with a
washer under the bolt head.
16. Slide the rear end of the tongue into the retractable receiver box until the pin hole in the box
aligns with one of the 2 pin holes in the sides of the tongue. Pass the hitch pin through and install
the ring clip.
800-295-0042 ext 206
MPG460XT
REFERENCE:
Trailer Wiring Color Code
• Brown = running lights
• Yellow = driver side stop / turn
• Green = passenger side stop / turn
• White = ground
2. Sandwich the license plate mounting
bracket between the driver side lamp
and the driver side tail lamp bracket.
Attach the tail light using the nuts
provided with the lamp kit. Then mount
the passenger side lamp.
1. Attach the tail lamp brackets to
the frame as shown using 3/8” x 1”
carriage head bolts and nuts. No
washers are needed.
LIGHT ASSEMBLY (Group 3)
3. Use the holes just above the
spring bracket to mount the amber
side lamps. Put the stud through
through the forward hole and the
wire through the rearward hole.
Tuck the wire so the lamp sits
flush on the frame.
MPG460G
REFERENCE:
Trailer Wiring Color Code
•Brown = running lights
•Yellow = left turn / left brake
•Green = right turn / right brake
•White = ground
2. Sandwich the license plate mounting
bracket between the left side lamp and the
left side tail lamp bracket. Attach the tail
light using the nuts provided with the lamp
kit. Then mount the right side lamp.
1. Attach the tail lamp brackets to
the frame as shown using 3/8” x 1”
carriage head bolts and nuts. No
washers are needed.
LIGHT ASSEMBLY (Group 3)
3. Use the holes just above the
spring bracket to mount the amber
side lamps. Put the stud through
the forward hole and the wire
through the rear hole. Tuck the wire
so the lamp sits flush on the frame.
L.E.D. REFERENCE:
Trailer Wiring Color Code
•Brown = running lights
•Yellow = left turn / left brake
•Green = right turn / right brake
•White = ground
2. Sandwich the license plate mounting
bracket between the left side lamp and the
left side tail lamp bracket. Bring the white
ground connector around and back over
lamp bolt. Attach/secure the tail light using
the nuts provided with the lamp kit. Then
mount the right side lamp.
3. Use the holes just above the spring
bracket to mount the amber side lamps.
Put the stud through the rear hole and
the wires through the front hole. Tuck
the wire so the lamp sits flush on the
frame. Attach the black ground
connector to lamp post and secure with
nuts provided if using an LED light.
technical@maloneautoracks.com
800-295-0042 ext.215
L.E.D. REFERENCE:
Trailer Wiring Color Code
•Brown = running lights
•Yellow = left turn / left brake
•Green = right turn / right brake
•White = ground
1. First attach the tail lamp brackets to the frame as shown
using 3/8” x 1” carriage head bolts and nuts. No washers
are needed.
2. Mount the drivers side lamp to the lamp bracket. Attach/
secure the license plate holder to the backside of the lamp
bracket as shown. Secure tail light using the nuts provided
with the light kit. Then mount the passengers side tail light.
3. Use the holes just above the spring bracket to mount the
amber side lights. First, push the wire leads through the
outside holes and the lamp stud through the center hole.
14
4. Routing the wiring harness.
- Route the GREEN/BROWN wire
along the RIGHT side of the frame.
- Route the YELLOW/BROWN wire
along the LEFT side of the frame.
5. Use the clips provided to secure the wire to the inside of
the frame channel as shown.
6. Position the
harness connector
off center close
to a frame rail as
shown. This holds
the connector up
at the frame during
trailering.
7. The white wire on the connector is not needed at this
location on the trailer. Clip it off flush with the connector.
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800-295-0042 ext.215
4. 4. Secure with the lamp stud nut.
5. Plug in the remaining wiring harness into the connection
behind the tongue. Looking at the end connections, route
the GREEN/BROWN/WHITE wire along the passengers
side. Route the YELLOW/BROWN/WHITE along the
drivers side as shown.
6. Next, we’ll route the wires through the cross members, One lead at a time, all the way through the
trailer to the tail lights.
800-295-0042 ext 206
MPG460XT
9. Connecting the side
lamps.
To control cutting between
two conductors without
damaging the wire or
yourself, press the wire
flat against the frame then
squarely push the blade tip
between the conductors until it hits the frame.
Then with the knife tip still held firmly against
the frame, pull the wire gently away from the
frame so the blade cuts between the wires.
This way you don’t get cut and the risk of
cutting too much is greatly reduced.
Divide only about 1/2” of wire. Set the knife
aside.
10. Grasp either side of the cut with your finger-
nails and pull to separate 3” of wire as shown.
11. Press the brown wire into the quick connector
as shown. Then insert the wire from the side
marker light fully into the 2nd opening. Use
pliers to squeeze the conductor blade down and
through the insulation. The blade cuts through the
insulation and connects the wires inside. Flip the
cover to lock the connector. Repeat on the other
side again using the brown wire.
8. Route the wires thru the
mid cross member as shown
then secure the harness in
place using the frame clips
provided.
technical@maloneautoracks.com
800-295-0042 ext.215
8. Use the clips provided to secure the wire to the inside of
the frame channel as shown.
7. With the wires routed all the way to the tail lights, rmly
grasp the wiring connections and plug-in matching colored
leads/wires. Repeat with all remaining lights.
NOTE: THESE UNUSED PLUGS ARE FOR AUXILIARY ACCESSORIES LIKE
THE MALONE MPG543 CHARGING UNIT AND/OR MPG539 FLOOD LIGHT
(NOT INCLUDED)
MPG539
MPG543
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MPG460XT
FENDER ASSEMBLY (Group 4)
1. Connect all 4 fender brackets to the fenders using 3/8” x 3/4” slot head
screws and nuts. Assemble with the nuts
to the inside of the fenders as shown. No
washers here. Fully tighten all 8 screws
and nuts.
Note: fenders are
symmetrical and fit on
either side of the trailer.
16 800-295-0042 ext. 215
MALONE
R
MPG460XT
3. Tighten bolts fully and repeat for other side.
Note that when bolting the mounting
brackets to the frame you will install a
washer on both sides, under the head of
each bolt and under each nut.
2. Using 3/8” x 1” bolts, washers on both
sides, and nuts, attach the fender brackets
to the slotted holes in the frame as shown.
NOTE you will use the center hole in the
bracket and the outside two slotted holes in
the frame.
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R
800-295-0042 ext. 215 17
800-295-0042 ext 206
MPG460XT
1. Assemble the tongue skid and safety
chain assembly with a 3/8” x 1-1/2” bolt as
shown. Use washers above and below the
chain ends.
COUPLER ASSEMBLY
(Group 5)
18 800-295-0042 ext. 215
MALONE
R
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