HEAVY DUTY TRAILER
MODEL 40597
ASSEMBLY AND OPERATING
INSTRUCTIONS
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 fitting 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
causing property damage, SERIOUS
PERSONAL INJURY, or DEATH.
®
3491 Mission Oaks Blvd., Camarillo, CA 93011
©
®
Copyright 2003 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, please call 1-800-444-3353.
REV 10/04
reflexes are impaired while taking drugs. If there is any doubt, do not attempt to
use this product.
5.
6.
USE EYE PROTECTION. Wear ANSI approved safety impact eye goggles when
assembling 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
caught in moving parts. Wear a protective hair covering to prevent long hair from
becoming caught in moving parts. If wearing a long-sleeve shirt, roll sleeves up
above elbows.
7.
DO NOT OVERREACH. Keep proper footing and balance at all times to prevent
tripping, falling, back injury, etc.
8.
9.
INDUSTRIAL APPLICATIONS MUST FOLLOW OSHA REQUIREMENTS.
STAY ALERT. Watch what you are doing at all times. Use common sense. Do
not use this product when you are tired or distracted from the job at hand.
10.
CHECK FOR DAMAGED PARTS. Before using this product, carefully check that
it will 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.
11.
REPLACEMENT PARTS AND ACCESSORIES: When servicing, use only identi-
cal replacement parts. Only use accessories intended for use with this product.
Approved accessories are available from Harbor Freight Tools.
12.
13.
14.
MAINTAIN THIS PRODUCT WITH CARE. Keep this product clean and dry for
better and safer performance.
MAINTENANCE: For your safety, service and maintenance should be performed
regularly by a qualified technician.
USE THE RIGHT TOOL FOR THE JOB. Do not attempt to force small equip-
ment to do the work of larger industrial equipment. There are certain applications
for which this equipment was designed. It will do the job better and more safely
at the capacity for which it was intended. Do not modify this equipment, and do
not use this equipment for a purpose for which it was not intended.
15.
WARNING: The warnings, precautions, and instructions discussed in this
manual 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.
SKU 40597
For technical questions, please call 1-800-444-3353.
PAGE 3
SPECIFIC PRODUCT WARNINGS AND PRECAUTIONS
1.
2.
TO AVOID PERSONAL INJURY AND/OR PROPERTY DAMAGE, DO NOT
EXCEED THE TRAILER’S MAXIMUM WEIGHT CAPACITY OF 1,800
POUNDS .
BEFORE EACH USE, ALWAYS EXAMINE THE TRAILER FOR PROPER TIRE
(part #81) AIR PRESSURE, DAMAGED TAIL LIGHTS (parts #80, #82), DAM-
AGED SIDE RUNNING LIGHTS (part #83), LOOSE BOLTS AND NUTS,
STRUCTURAL CRACKS, BENDS, AND ANY OTHER CONDITION THAT MAY
AFFECT ITS SAFE OPERATION. Do not use the Trailer even if minor damage
appears.
3.
4.
NEVER ALLOW ADULTS, CHILDREN, OR PETS TO RIDE IN THE TRAILER.
BEFORE EACH USE, ALWAYS ATTACH THE SAFETY CHAIN (part #11) OF
THE TRAILER TO THE TOWING VEHICLE. 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.
5.
6.
ALWAYS CHECK TO MAKE SURE THE PAYLOAD BEING TRANSPORTED IS
PROPERLY AND SAFELY SECURED IN THE TRAILER. Load the Trailer
evenly from side to side with 60% of the load forward of the Axle (part #9).
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.
7.
MAKE SURE THE COUPLER (part #1) AND THE VEHICLE’S HITCH BALL
(not included) ARE OF EQUAL MATING SIZE (2”) AND ARE RATED EQUAL
TO OR GREATER THAN THE WEIGHT OF THE TRAILER AND ITS PAYLOAD.
8.
9.
DO NOT EXCEED 45 MILES PER HOUR WHEN TOWING THE TRAILER.
Excess speed is a major cause of vehicle-trailer accidents.
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.
10.
WHENEVER POSSIBLE, PARK THE TRAILER ON A FLAT, LEVEL, PAVED,
SURFACE AND CHOCK BOTH TIRES TO KEEP THE TRAILER FROM
ACCIDENTLY MOVING.
SKU 40597
For technical questions, please call 1-800-444-3353.
PAGE 4
11.
12.
TRAILER LICENSING NOTICE: Some states may consider this Trailer a vehicle
requiring registration, licensing, and titling. Check with your State Department of
Motor Vehicles for information and guidance on registering, licensing, and titling
the Trailer.
MAINTAIN LABELS AND NAMEPLATES ON THE TRAILER. These carry
important information. If unreadable or missing, contact Harbor Freight Tools for
a replacement.
UNPACKING
When unpacking, check to make sure all the parts shown on the Parts List (page 19) are
included. If any parts are missing or broken, please call Harbor Freight Tools at the
number shown on the cover of this manual as soon as possible.
ASSEMBLY INSTRUCTIONS
NOTE: For additional references to the parts listed on the following pages, refer to the
Assembly Diagram (page 20).
1.
On a flat, level, surface, lay out one Front Left Side Rail (part #3), one Front
Right Side Rail (part #4), one Front Cross Member (part #5), and two Cross
Members (part #20). Assemble the parts, using the Bolts (part #47), Flat Wash-
ers (part #70), Spring Washers (part #66), and Nuts (part #61). (See Figure A.)
TO CENTER OF TRAILER
CROSS MEMBER
(#20)
FRONT RIGHT SIDE RAIL
(#4)
CROSS MEMBER
(#20)
47
61
66
70
FRONT LEFT SIDE RAIL
(#3)
FRONT CROSS
MEMBER
(#5)
TO FRONT OF TRAILER
FIGURE A
SKU 40597
For technical questions, please call 1-800-444-3353.
PAGE 5
2.
Attach the Right Angle Iron (part #23A) to the Front Right Side Rail (part #4) and
attach the Left Angle Iron (part #23) to the Front Left Side Rail (part #3), using
the Bolts (part #52), Spring Washers (part #67), and Nuts (part #62).
(See Figure B.)
3.
4.
Attach one Connecting Rail (part #2) to the Front Left Side Rail (part #3) and
another Connecting Rail to the Front Right Side Rail (part #4), using the Bolts
(part #47), Spring Washers (part #66), and Nuts (part #61). (See Figure B.)
Insert the two “L” Latches (part #29) through the two Connecting Rails (part #2)
and Front Cross Member (part #5). Secure the “L” Latches using the two “R” Pins
(part #30). (See Figure B.)
5.
Attach the “T” Plate (part #24), Chain (part #11), and Coupler (part #1) to the two
Connecting Rails (part #2), using the Bolts (part #48), Flat Washers (part #70),
Spring Washers (part #66), and Nuts (part #61). (See Figure B.)
FRONT RIGHT SIDE RAIL (#4)
RIGHT ANGLE IRON (#23A)
47
61
66
FRONT
LEFT
SIDE
RAIL
(#3)
“R” PIN (#30)
52
62
67
“L” LATCH
(#29)
FRONT CROSS
MEMBER (#5)
CONNECTING
RAIL
47
61
66
70
LEFT ANGLE IRON
(#23)
(#2)
“R” PIN (#30)
COUPLER
(#1)
“L” LATCH (#29)
CONNECTING
RAIL
“T” PLATE
(#24)
48
61
66
70
(#2)
CHAIN (#11)
FIGURE B
6.
7.
Lay out one Rear Left Side Rail (part #21), one Rear Right Side Rail (part #22),
and three Cross Members (part #20). Assemble the parts, using the Bolts
(part #47), Flat Washers (part #70), Spring Washers (part #66), and Nuts
(part #61). (See Figure C, next page.)
Assemble the front portion and the rear portion of the Trailer, using the Bolts
(part #48) on the top flanges, the Bolts (part #85) on the lower flanges, Flat
Washers (part #70), Spring Washers (part #66), and Nuts (part #61).
(See Figure D, next page.)
SKU 40597
For technical questions, please call 1-800-444-3353.
PAGE 6
TO REAR OF TRAILER
REAR RIGHT SIDE RAIL
(#22)
CROSS MEMBER
(#20)
CROSS MEMBER
(#20)
47
61
66
70
CROSS MEMBER
(#20)
REAR LEFT SIDE RAIL
(#21)
TO CENTER OF TRAILER
FIGURE C
48
61
66
70
48
61
66
70
FRONT PORTION
85
85
85
85
48
48
61
66
70
REAR PORTION
61
66
70
FIGURE D
8.
Attach the Left Spring Hanger (part #6) to the Front and Rear Left Side Rails
(parts #3, #21), using the Bolts (part #46), Flat Washers (part #70), Spring Wash-
ers (part #66), and Nuts (part #61). Then, attach the Right Spring Hanger
(part #7) to the Front and Rear Right Side Rails (parts #4, #22), using the Bolts
(part #46), Flat Washers (part #70), Spring Washers (part #66), and Nuts
(part #61). (See Figure E, next page.)
SKU 40597
For technical questions, please call 1-800-444-3353.
PAGE 7
REAR RIGHT
SIDE RAIL
(#22)
FRONT RIGHT
SIDE RAIL
(#4)
REAR LEFT
SIDE RAIL
(#21)
FRONT LEFT
SIDE RAIL
(#3)
LEFT SPRING
HANGER (#6)
46
61
66
70
FENDER
(#26)
54
63
46
61
66
70
54
63
70
66
61
SPRING
PLATE
(#27)
AXLE (#9)
HUB (#12, #75, #79)
WHEEL (#81)
FENDER
SEAT
ASSY.
(#25)
47
61
66
LEAF
SPRING
(#8)
NOTE:
PRIOR TO USING,
LUBRICATE THE
HUB ASSEMBLY.
(#12, #75, #79)
“U-BOLT (#28)
BEARING (#76)
WASHER (#34)
DUST COVER (#33)
NUT (#64)
COTTER PIN (#72)
See note on Page 9
FIGURE E
9.
Attach the two Fender Seats (part #25) to the Left and Right Spring Hangers
(parts #6, #7), using the Bolts (part #47), Spring Washers (part #66), and Nuts
(part #61). Then attach the two Fenders (part #26) to the two Fender Seats,
using the Bolts (part #47), Spring Washers (part #66), and Nuts (part #61).
(See Figure E.)
10.
11.
Attach the two Leaf Springs (part #8) to the Left and Right Spring Hangers
(parts #6, #7), using the Bolts (part #54), and Nylon Nuts (part #63). Insert a
Cotter Pin (part #72) through the holes in the end of the Bolts and spread the
Cotter Pins. (See Figure E.)
With assistance, turn the Trailer upside down. Place the Axle (part #9) on top
of both Leaf Springs (part #8). Place the two Spring Plates (part #27) below
the Leaf Springs. On each end of the Axle, insert two U-Bolts (part #28)
downward over the Axle and through the mounting holes in each of the Spring
Plates. Then secure the Axle and Leaf Springs, using Flat Washers (part #70),
Spring Washers (part #66), and Nuts (part #61). (See Figure F, next page.)
SKU 40597
For technical questions, please call 1-800-444-3353.
PAGE 8
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