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Harbor Freight Tools 40597 manual

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Table of contents for the manual

  • Page 1

    HEA VY DUTY TRAILER MODEL 40597 ASSEMBL Y AND OPERA TING INSTRUCTIONS 3491 Mission Oaks Blvd., Camar illo , CA 93011 Visit our W eb site at http//www .harborfreight.com Cop yright © 2003 b y Harbor F reight T ools ® . All rights reser v ed. No por tion of this manual or an y ar twork contained herein may be reproduced in an y shape or f o rm with[...]

  • Page 2

    SKU 40597 For technical questions, please call 1-800-444-3353. PAGE 2 PR ODUCT SPECIFICA TIONS SA VE THIS MANU AL Y ou will need this manual f or the saf ety warnings and precautions, assembl y , operating, inspection, maintenance and cleaning procedures, parts list and as- sembl y diagram. K eep your in voice with this manual. Write the in voice n[...]

  • Page 3

    SKU 40597 For technical questions, please call 1-800-444-3353. PAGE 3 assembling this product. ANSI approv ed saf ety impact eye goggles are a v ailab le from Harbor F reight T ools. 6. DRESS SAFEL Y . Do not wear loose clothing or jewelr y , as the y can become caught in moving par t s . Wear a protective hair co ve ring to pre vent long hair from[...]

  • Page 4

    SKU 40597 For technical questions, please call 1-800-444-3353. PAGE 4 SPECIFIC PR ODUCT W ARNINGS AND PRECA UTIONS 1. T O A V OID PERSONAL INJUR Y AND/OR PROPERTY D AM A GE, DO N O T EXCEED THE TRAILER’S MAXIMUM WEIGHT CAP A CITY OF 1,800 POUNDS . 2. BEFORE EA CH USE, AL W A YS EXAMINE THE TRAILER FOR PR OPER TIRE (par t #81) AIR PRESSURE, D A MA[...]

  • Page 5

    SKU 40597 For technical questions, please call 1-800-444-3353. PAGE 5 11. TRAILER LICENSING NO TICE: Some states ma y consider this T railer a v ehicle requiring registration, licensing, and titling. Check with your State Department of Motor V ehicles for inf or mation and guidance on registering, licensing, and titling the T r ailer . 12. MAINT AI[...]

  • Page 6

    SKU 40597 For technical questions, please call 1-800-444-3353. PAGE 6 3. 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), Spr ing Washers (par t #66), and Nuts (par t #61). (See Figure B.) 4. Insert the two “L” Latches (part[...]

  • Page 7

    SKU 40597 For technical questions, please call 1-800-444-3353. PAGE 7 T O CENTER OF TRAILER T O REAR OF TRAILER REAR RIGHT SIDE RAIL (#22) REAR LEFT SIDE RAIL (#21) CROSS MEMBER (#20) CROSS MEMBER (#20) CROSS MEMBER (#20) 47 61 66 70 FIGURE C FRONT PORTION REAR PORTION 48 61 66 70 48 61 66 70 48 61 66 70 48 61 66 70 85 85 85 85 FIGURE D 8. Attach t[...]

  • Page 8

    SKU 40597 For technical questions, please call 1-800-444-3353. PAGE 8 9. Attach the two Fender Seats (part #25) to the Left and Right Spring Hangers (par ts #6, #7), using the Bolts (par t #47), Spring Washers (par t #66), and Nuts (par t #61). Then attach the two F enders (par t #26) to the two F ender Seats, using the Bolts (par t #47), Spr ing W[...]

  • Page 9

    SKU 40597 For technical questions, please call 1-800-444-3353. PAGE 9 12. Inser t a Hub (par t #12) onto the spindle at each end of the Axle (par t # 9). Inser t the Bearings (par t #76) onto the spindles of both ends of the Axle. Inser t a W asher (par t #34) onto each spindle of the Axle. Then secure the Hub and Bearing assemb lies, using the Nut[...]

  • Page 10

    SKU 40597 For technical questions, please call 1-800-444-3353. PAGE 10 17. Attach a T ail Light Bracket (par t #31) to the Rear Left Side Rail (par t #21), using the Bolts (par t #47), Spring W ashers (par t #66), and Nuts (par t #61). Then, repeat this Step to attach the remaining T ail Light Brack et to the Rear Right Side Rail (part #22). (See F[...]

  • Page 11

    SKU 40597 For technical questions, please call 1-800-444-3353. PAGE 11 21. Leav e about 18” of wire beyond the Coupler (par t #1), and r un the Wiring Harness along the inside of the Connection Rail (par t #2) to the F ront Right Side Rail (par t #4). Then, split the Y ellow/Brown Wires from the Green/ Brown Wires. (See Figure H.) 22. Run the Y e[...]

  • Page 12

    SKU 40597 For technical questions, please call 1-800-444-3353. PAGE 12 WIRING DIA GRAM FOR RUNNING LIGHTS[...]

  • Page 13

    SKU 40597 For technical questions, please call 1-800-444-3353. PAGE 13 23. Connect the Wire Lead from the two Side Running Lights (par t #83) to the Brown Wire on each side of the T r ailer . Then, inser t Wire Clips along the entire length of the Side Rails of the T railer to hold do w n the Wiring Har ness . (See Figure H.) 24. Run the Y ellow/Br[...]

  • Page 14

    SKU 40597 For technical questions, please call 1-800-444-3353. PAGE 14 3-1/2” X 1” S LO TS ST AKE SLO T 3/4” PL YW OOD 3/8” DIA. MOUNTING HOLES 3/8” CROSS HEAD BOL T 3/8” FLA T W ASHER 3/4” PL YW OOD 3/8” SPRING W ASHER 3/8” HEX NUT FIGURE I F. Qty . 8: 3/8” x 2-3/8” He x Bolt (not included). G. Qty . 48: 3/8” x 2-3/8” He [...]

  • Page 15

    SKU 40597 For technical questions, please call 1-800-444-3353. PAGE 15 3/8” DIAMETER 2 1 . 6 0.75 0.75 3/8” DIAMETER 1.25 1 . 2 5 2 2 0.75 2 94.5 1.25 R2 18.5825 2 50.835 2 18.5825 3.5 2 8 2 24 2 8 2 3.5 2 27 1.25 6 2 6.5 2 6.5 2 3.5 SIDE RAIL ST AKE FRONT END B ACK END RAIL CONNECTING PLA TE FIGURE J 3/8” FLA T W ASHER 3/8” X 3-3/8” CR O[...]

  • Page 16

    SKU 40597 For technical questions, please call 1-800-444-3353. PAGE 16 35. Attach the Connecting Plates to the Side Rails and F ront End/Bac k End Rails, using 3/8” x 1-3/4” Cross Head Bolts and 3/8” Nuts. (See Figure K) 36. With assistance , lift the T railer rail o v er the T r ailer and lower the Stak es into the Stak e Slots of the T rail[...]

  • Page 17

    SKU 40597 For technical questions, please call 1-800-444-3353. PAGE 17 ATT ACHING TRAILER T O VEHICLE OPERA TING INSTRUCTIONS 1. Only use a 2” ball hitch (not included) on the towing vehicle. (See Figure M.) 2. W ARNING! The T railer load should never exceed 1800 pounds or exceed the T railer’ s Bed siz e . 3. Make sure to have a qualified tech[...]

  • Page 18

    SKU 40597 For technical questions, please call 1-800-444-3353. PAGE 18 5. Connect the T ail Light Wir ing Assemb ly to the towing v ehicle’ s 12 V olt DC system. NO TE: Make sure to consult the operator’ s ma nual of the to wing vehicle f or proper connection instructions. 6. When towing the T railer ov er long distances stop and chec k the tig[...]

  • Page 19

    SKU 40597 For technical questions, please call 1-800-444-3353. PAGE 19 P AR TS LIST NO TE: Some par ts are listed and sho wn f or illustration purposes only , and are not avail- ab le individually as replacement par t s. # t r a Pn o i t p i r c s e D. y t Q# t r a Pn o i t p i r c s e D. y t Q 1r e l p u o C1 3 3r e v o C t s u D2 2l i a R g n i t[...]

  • Page 20

    SKU 40597 For technical questions, please call 1-800-444-3353. PAGE 20 ASSEMBL Y DIA GRAM 84: WIRING HARNESS NO T SHO WN. 33 64/72 34 76 81 12/75/79 29/30 NO TE: P RIOR T O USING, LUBRICA TE THE BEARINGS THR OUGH THE GREASE FITTING ON THE INSID E OF THE HUB. 83 2 11 48 61 66 70 24 1 2 47 61 66 70 5 47 61 66 70 52 62 67 23A 47 61 66 4 85 85 85 85 47[...]

  • Page 21

    SKU 40597 For technical questions, please call 1-800-444-3353. PAGE 21 Bearing P ac king Instructions Impor tant Read and adhere to the following instructions; failure to read and obey all of the f ollo wing instructions COMPLETEL Y will v oid the warranty and can result in damage to the trailer , proper ty damage, or SERIOUS PERSONAL INJUR Y. When[...]