Tuff stuff BASECAMP User manual

TUFF STUFF® BASECAMP TRAILER
OWNERS MANUAL
READ MANUAL & KEEP FOR YOUR RECORDS

TUFF STUFF® BASECAMP TRAILER
OWNERS MANUAL
MODEL # TS-TRAILER-BC
Congratulations on your new Tuff Stuff® BASECAMP Trailer. The warnings, cautions and
instructions discussed in this manual cannot cover all possible conditions and/or situations that
may occur. It is understood that the user of this expedition trailer uses common sense and
caution. Please get professional training if you are unaware on how to safely operate this Tuff
Stuff® BASECAMP Trailer or call us directly at 1-866-220-0171 or email us at
[e-mail]
If you are new at towing a trailer please go to "Towing a Trailer - being equipped for safety"
through the National Highway Traffic Safety Administration
https://one.nhtsa.gov/cars/problems/Equipment/towing/index.htm
DMV Requirements:
Most States require that the trailer must be registered with the DMV (Department of Motor
Vehicles). When registering your trailer, you may need an invoice showing the purchase price
of the trailer. Be sure to request a full invoice from the dealer when making your purchase or
request one after reading this information.
Tuff Stuff Overland is registered with the SAE and will issue the trailer a VIN # as well as a
MCO/MSO certificate that must be taken with you to the DMV for registration or your dealer
will do this for you.
During registration you will be issued a title, VIN sticker and license plate. Please note, some
states may vary in their compliance procedures these are just basic guidelines.
This is the manufacturers plate that you will have on the left side front tongue of the trailer.
The plate will include the following Information:
1. Manufacturer Date
2. Model #
3. Serial #
4. Relevant information about the trailer
5. Vin Number for DMV

This is what your Certificate Of Origin will look like once you have purchased your Trailer
Please note from time to time our information and product will be updated. We are not responsible for any misprints.
Please contact our customer care if you have any additional questions or concerns.
Product color, components, digital components may change, installation information may change.

MANUFACTURERS WARRANTY
The warranty period begins on the date the trailer is sold to the customer.
BASIC WARRANTY INFORMATION
The warranty coverage is 12 months on manufacturer defects only.
This warranty covers any parts needed to correct defects in materials or workmanship of all
parts and components of each new Tuff Stuff® BASECAMP Trailer. Please note, there will be
exclusions to this warranty.
MANUFACTURERS COVERAGE OF PARTS
Tuff Stuff® Warranty parts will be sent at no charge except for tires and wheels.
Tuff Stuff® Overland reserves the right to make changes at any time (without notice) to
production and service parts in their specifications, colors, and materials, including those used
in connection with warranty repairs. For this reason, at Tuff Stuff ® discretion, functionally
equivalent replacement parts may be used that do not exactly match the original production
part.
CUSTOMER TO MAINTAIN SERVICE RECORDS / REPAIR
As a condition of this warranty you are responsible for properly using, maintaining and caring
for your expedition trailer. Retain copies of all maintenance records including receipts.
Evidence of maintenance performance is required to be presented to Tuff Stuff® in connection
with related warranty repairs.
WHAT IS NOT COVERED - GENERAL EXCLUSIONS
This warranty does not cover damage, failures or corrosion resulting from or caused by:
-Failure to operate the vehicle safely in all conditions.
-Misuse of the trailer or parts.
-Failure of a component not covered by warranty.
-Damage due to terrain such as rocks, trees, ditches.
-Theft, vandalism, fire, or flooding.
-Accident, collision, abuse.
DAMAGE, FAILURES OR CORROSION FROM ENVIRONMENTAL CONDITIONS
This warranty does not cover damage, failures or corrosion resulting from or caused by:
stone chipping, chemical fallout (acid rain), tree sap, salt, hail, windstorm, lightning, flood or
other environmental conditions that may damage the trailer.
MAINTENANCE SERVICE EXPENSE
This warranty does not cover normal maintenance services such as cleaning and polishing,
wheel alignment, lubricants, worn brake, shoes, drums, water tank etc.

IF ASSEMBLY IS REQUIRED ONLY Tuff Stuff® BASECAMP Trailer is specially designed to
be delivered to any location that has a forklift to lift the pallet off the delivery vehicle. Once the
pallet is on level ground the metal pallet is designed to have the top removed and the two front
bars removed allowing the trailer to roll freely off the pallet.
To safely move the trailer off the pallet, once all of the accessories have been removed from the
packing, install the front tongue with 6 bolts (see diagram). Place the draw-bar on the Trailer
Tongue and secure trailer to your vehicle. Drive vehicle forward to allow trailer to roll off the
metal pallet (make sure pallet is secure and no one is in the way of the pallet if it should move).
Once the pallet is no longer needed you can recycle the pallet or use for future storage.
NOTE : One professional person cannot safely do this alone, please have help.
1) Remove water tank / top storage draw and front storage drawer - place aside for later
installation.
2) Unbolt the 4 self drilled tapping screws on support to remove top pallet
3) Using the top loops, raise top level off the pallet exposing the tongue
a) Tongue can be removed by cutting the wire on the front and removing 4 bolts at the
back holding it to the top pallet
4) Remove tongue and place aside to be used to pull trailer off the pallet
5) Facing the front of the trailer remove the side bar and stabilizing bars under the trailer
6) Remove the final side exposing the front of the trailer
7) Locate the installation bolts for the tongue located in the left middle compartment upper
draw. The label will say "Tongue-Chassis"
8) Assemble the tongue to the trailer and install the hitch to the tongue
a) All bolts and accessories will be in a separately packed brown box
Continue on next page
WHAT DO I EXPECT WHEN I RECEIVE MY expedition TRAILER
There are three (2) ways that you can receive this expedition Trailer.
1) Fully Assembled Ready to pick up from Dealer (MOST COMMON WAY)
2) On a 90% together Metal Pallet System- Special order by dealer.
USE A PROFESSIONAL ONLY FOR ASSEMBLY

#7 Continued
Assemble tongue to trailer at these bolt
locations. 1 person cannot do this
please make sure you have help.
After you have installed the tongue
install the guide wheel, hand brake
and hitch.
Connect the draw-bar onto the trailer body with the hardware bolts in this package.
Qty 4 x M16*35 and Qty 4 x M12*30.
INSTALL STABALIZING LEGS
Remove the hardware pack labeled "STABALIZING LEGS" and use this hardware to
install the legs onto the mounting brackets. There are four (4) legs, two (2) in the front
and two (2) in the back.
Stabilizing legs can be
manually tilted up or
down. Only have in the
stabilizing position
when the trailer is
parked and being used
to camp. Never drive
with the stabilizing legs
down.

INSTALL HITCH COUPLER
Locate hardware that is market "HITCH COUPLER"
INSTALL JOCKEY WHEEL
Locate hardware that is market "JOCKEY WHEEL"
The "Jockey Wheel" must only be in the DOWN position to move the trailer to the tow vehicle.
When the trailer has been connected to the tow vehicle, Turn the crank on top to raise up the
wheel until it is off the ground and all the weight is on the tow vehicle, then pull pin and move
the jockey wheel into the horizontal position for towing. NEVER leave the jockey wheel
pointing towards the ground when you tow.

Before the trailer can be freed from the pallet you have to release and remove the last 4 bolts
holding the back of the trailer to the pallet. Refer to the image below for the loaction of these
bolts.

Once you have installed the tongue and hitch to the car, make sure that the brake is in the
"OFF" position and you have connected the chains and electrical to your vehicle before you
attempt to drive the trailer off the pallet. Make sure there is nothing obstructing the trailer and
slowly drive the trailer off the pallet.
1. Make sure you do not hit the sides of the pallet and damage the trailer.
2. Make sure that there is no one around the area that can be hurt - always think safety first.
3. Make sure that there are no obstructions in the way that the trailer will hit or roll over.
4. Drive slowly and safely when removing the trailer from the pallet.
YOU ARE NOW ABLE TO DRIVE THE TRAILER HOME AND COMPLETE THE INSTALLATION
You will have to install the following to complete the Trailer
•Installation of the water tank.
•Installation of the front storage compartment.
•Installation of the hand brake.
•Installation of the storage compartment under the roof top tent.
•Installation of the roof top tent rack and awning rack.
INSTALLING THE WATER TANK
Take out the hardware that is labeled "WATER TANK"
Diagram is UPSIDE DOWN for
demonstration purposes only
DO NOT turn trailer upside
down for installation.
Place the Water Tank skid plate and two (2) steel straps on the water tank. Once done,
attach the 4 bolts / washers and spring washers to the underneath of the trailer mounts as
shown in the diagram below.

INSTALLING THE STORAGE BOX
Take out the hardware that is labeled "TOOLBOX"
Using the hardware provided the front storage box or tool box can be fixed to the trailer by
installing the four (4) bolts to the holes shown in the diagram below.

INSTALLING THE HAND BRAKE
Take out the hardware that is labeled "HAND BRAKE"
The hardware provided in the pack (M12*30 bolt / M12 flat washer / M12 lock nut) will allow
you to install the hand brake onto the front of the draw-bar as shown in the picture. Move the
hand brake into the "RELEASE" or "DOWN" position.
Take out hardware labeled "CLAMP FOR HAND BRAKE"

INSTALLING THE HAND BRAKE CABLE - Continued.
Pass the brake cable through the brake cable guide rings on both sides of the trailer and then
connect to the "brake cable connection plate" located on each tire hub. Use the wire clamps
as shown on each side of the "brake cable connection".
Use this type of clamp provided to secure the cable. Loop the cable provided as in picture B
and C above.
A B C
INSTALLING THE TOP STORAGE BOX
Take out the hardware that is labeled "TOP BOX"

INSTALLATION "TOP STORAGE BOX" continued.
Before the Storage Box can be installed, first remove the drawer from the top storage box as
pictured below.
Just like a regular sliding drawer, once you have the drawer out, press the black side lever to
unlock the sliders. Remove the drawer from the box and place in a safe location so that it does
not get damaged. Place cardboard / paper or a moving blanket on the ground so that the paint
does not get damaged.
Use the hardware provide labeled "TOP BOX" to attach the Box Frame onto the top of the
trailer as shown in the diagram below. NOTE: all holes have been "pre-drilled".

INSTALLATION "TOP STORAGE BOX" continued.
Once you have the TOP BOX ready for the storage drawer, align the sliders and slide the drawer
into the sliding rails. Make sure they are aligned correctly and lock into place. Open and close at
least seven (7) times to make sure that the drawer is locked in place.
INSTALLING THE TENT ROOFTOP RACK & AWNING MOUNT
Take out the hardware that is labeled "TENT BAR MOUNTING SEAT"
The hardware provided is to mount the four (4) mounting brackets provided. The location 1 - 2 -
3 - 4 on the diagram will use the M6*40 bolt / M6 flat washer / M6 lock nut a total of ten (10)
holes. The location 5 - 6 - 7 - 8 will use the M6*25 bolts / M6 flat washer and M6 lock nut a total
of six (6) holes.
VERY IMPORTANT - Be sure to use silicon chalking to waterproof the bolt holes.

Take out the hardware that is labeled "TENT BAR PIN"
The top bars that the roof top tent fits onto is adjustable. Use the provided pins to lock the
top bars to the base brackets. Two (2) pins per side are required. You are able to start in the
bottom position for travel but once at base camp, raise the height of tent and this will allow for
awning room and ladder to be used correctly.
INSTALLING THE TENT ROOFTOP RACK & AWNING MOUNT continued
NOTE: YOU MUST SILICON under the Tent Bars to waterproof those holes. It is a good practice
to Silicon all screw Holes to watertight this trailer.
There is a RIGHT and LEFT SIDE for these brackets so they are not Universal.

Take out the hardware that is labeled "AWNING BRACKET PIN"
There are two (2) parts to the awning bracket making it adjustable. Use the pins provided to
connect brackets to tent bars already installed. You can place the awning on the right or the left
depending where you are placing tent to be opened. Two (2) pins are required on each side.
NOTE: There is a welded twist locking bolt with plastic top that will lock the awning
bracket 1 ARM's so they do not rattle. Lock down tightly when positioned.
The Awning can be placed on the Right or left side of
the Trailer. We suggest you place the awning "OVER
THE KITCHEN" system so that you do not hit your
head on the tent.
If Facing from the back - the tent
should open to the right over the
"CONTROL CENTER" rather than
over the kitchen.

INSTALLING THE WATER HOSE
You will be provided a BLUE water connection hose with a quick connector on both sides.
Locate rubber cap protecting the water connection and remove this cap exposing
stainless quick connector.
Push in the sleeve of quick connector and plug the male end of the quick connector in until
cover closes onto the connection

To connect the water faucet when being used, remove the rubber cap as shown located
under kitchen section.
Plug in the male quick connector as shown below.
To use the water in the sink make sure there is water in the tank, the water pump has been
turned on and both quick connections are in place then the water will run freely into the sink.
NOTE: Your sink has a drain hose that must be
installed each time you use the sink to allow
water to flow into a bucket or drain onto the
ground. It will be attached to the bottom of the
sink by screwing it onto male threaded end of
sink. You will NOT be able to close the kitchen if
the drain hose is attached.

INSTALLING THE WATER PIPE TANK CONNECTION
From the water fill plug there is a hose that leads down to water tank. A "water pipe clamp" is
supplied in the package, remove and place over the connection between water fill hose and
water tank. Make sure that the hose is all the way over water tank connection and then tighten
clamp.
INSTALLING THE WATER PIPE OUTLET CONNECTION
The water pipe outlet location is on the bottom of the tank below water tank inlet location as
pictured above.
1) Remove locking nut from the water tank
2) Slide water pipe over the fitting
3) Slide the locking nut back over fitting with the pipe securely over male fitting
4) Fasten nut onto the water tank fitting

INSTALLING THE SOLAR PANEL PLUG
We have provided you with a SOLAR PANEL plug and quick connector to make your solar
panels work with the SOLAR ready trailer. The solar panel quick connector plug is located in
the back right of trailer as shown in the picture below.
Solar panel connection: Open the solar socket by rotating the plastic protection cover. Plug in
the solar connection cable. The solar connection cable will have a quick connector on the end
that can be connected to solar panels.
Attach male connector to female connector then screw on and attach solar panels.
Fit On Secure connection Screw down cap Ready for SOLAR