KIT ASSEMBLY INSTRUCTIONS

Transcription

1 JUMPING JACK TRAILER KIT KIT ASSEMBLY INSTRUCTIONS A torque wrench (provided in the in-store tool kit) is required to assemble this trailer kit. Torque is a twisting (ft.-lb.).copy force measured in foot-pounds Keep this Identification Number in case you must contact our Customer Service Department. 1

2 PARTS & HARDWARE LIST JUMPING JACK TRAILER KIT FIRST TIME SET-UP PARTS ID Description Qty BJE Trailer Assembly (not shown in Parts Identifier) 1 BIF Tongue Weldment/Swivel Jack Assembly 1 BJD Front Gate 1 BIG TONGUE INSTALLATION HARDWARE BIE Front Backer Plate 2 BID Rear Backer Plate 2 BIC 1/2 x 1 1/4 Hex Bolt 8 BIB 1/2 Top Lock Nut 8 AOR 1/2 Flat Washer 8 BST Gate Pin 1 Parts shown at 4% actual size Hardware shown at 50% actual size BIE (x2) Front Backer Plate Hardware shown at actual size BIC (x8) 1/2 x 1 1/4 Hex Bolt Socket Wrench with 3/4 & 3/8 Shallow Sockets AOR (x8) 1/2 Flat Washer PARTS IDENTIFIER TOOLS REQUIRED FOR THIS ASSEMBLY BJD (x1) Front Gate HARDWARE IDENTIFIER BIB (x8) 1/2 Top Lock Nut BIF (x1) Tongue Weldment/Swivel Jack Assembly BID (x2) Rear Backer Plate (1)Copy Torque Wrench Wire Cutters Safety Glasses BST (x1) Gate Pin (1) (1) (1 pair for each person) INSTRUCTION # C 6/09/2010 2

3 1 TONGUE INSTALLATION Hardware shown at 50% actual size HARDWARE REQUIRED BIE (x2) Front Backer Plate Hardware shown at actual size BID (x2) Rear Backer Plate BIC (x8) 1/2 x 1 1/4 Hex Bolt AOR (x8) 1/2 Flat Washer BIB (x8) 1/2 Top Lock Nut Parts shown at 4% actual size PARTS REQUIRED BIF (x1) Tongue Weldment/Swivel Jack Assembly TOOLS REQUIRED Socket Wrench with 3/4 & 3/8 Shallow Sockets Torque Wrench Wire Cutters Safety Glasses (1) (1) (1) (1 pair for each person) 3

4 NO HARDWARE REQUIRED FOR THIS PAGE 1.1 TWO PEOPLE REQUIRED FOR THIS STEP Using a pair of wire cutters, clip the Zip Ties holding the Tongue and the Front Gate to the Trailer. Remove the Tongue Weldment/Swivel Jack Assembly (BIF), the Front Gate, and the Instructions from the Trailer Assembly (BJE). BIF BJE 1.2 Note the two hooks on the sides of the Tongue. These will be connected up under the front of the Trailer. Hooks 4

5 NO HARDWARE REQUIRED FOR THIS PAGE 1.3 TWO PEOPLE REQUIRED FOR THIS STEP Place the Tongue Assembly under the Trailer as shown. 1.4 Note: Ensure Stabilizer Jacks are down prior to assembly. CAUTION Ensure rear Stabilizer Jack is down prior to assembly. Connect the Tongue Assembly Hooks up over the lip on the front of the Trailer as shown. Center the Tongue Assembly so the ends are flush with the sides of the Trailer.!! Note: Tongue Hooks go up over ridge underneath the Trailer. Note: Once the Tongue is in place, it should stay in place while you secure it to the Trailer. 5

6 BIE (x2) (Not to scale) BIC (x4) BIB (x4) AOR (x4) 1.5 Insert two 1/2 x 1 1/4 Hex Bolts (BIC) through the holes in a Front Backer Plate (BIE) so the heads of the bolts rest down inside the Backer Plate. BIC BIC BIE 1.6 From under the Trailer, insert the Bolts in the Backer Plate into the holes in the Frame above the Tongue as shown. Place a 1/2 Flat Washer (AOR) over each Bolt, but only hand tighten the two 1/2 Top Lock Nuts (BIB). Repeat steps for the second Front Backer Plate.! AOR BIB Note: Only hand tighten the Nuts in this step. AOR BIB CAUTION Do not clamp down Backer Plate over Wiring Harness. Gently pull Wiring Harness away from Bolts and Backer Plate while performing this step. 6

7 3/4 3/4 BID (x2) (Not to scale) BIC (x4) BIB (x4) AOR (x4) 1.7 Insert two 1/2 x 1 1/4 Hex Bolts (BIC) through the holes in a Rear Backer Plate (BID) so the heads of the bolts rest down inside the Backer Plate. BIC BIC BID 1.8 From under the Trailer, insert the Bolts in the Backer Plate into the holes in the Frame above both ends of the Tongue as shown. Place a 1/2 Flat Washer (AOR) over each Bolt, but only hand tighten the two 1/2 Top Lock Nuts (BIB). Repeat steps for the second Rear Backer Plate. Once all Bolts are in place, use a Socket Wrench with a 3/4 Socket to tighten the Nuts. The walls of the Backer Plates will keep the Bolts from spinning. Then, use a Torque Wrench to tighten all eight Nuts to 80 ft.-lb. (Torque). 80 ft.-lb.! Note: Tighten all eight Nuts to 80 ft./lb. (Torque).! AOR BIB Note: Torque is a twisting force measured in foot-pounds (ft.-lb.). 7 CAUTION Do not clamp down Backer Plate over Wiring Harness. Gently pull Wiring Harness away from Bolts and Backer Plate while performing this step.

8 NO HARDWARE REQUIRED FOR THIS PAGE 1.9 Turn up the rear Stabilizer Jack you put down in Section 1.3. Pull out the Locking Pin on the Swivel Jack to disengage the locking mechanism. Locking Pin 1.10 Rotate the Swivel Jack downward until the Locking Pin snaps into place. Rotate the Hand Crank on the Swivel Jack until the Leg is just above the ground. Hand Crank Leg 8

9 NO HARDWARE REQUIRED FOR THIS PAGE 1.11 Remove the Front Gate Lanyards from the Leg, and remove the Leg from the Trailer. Discard the Leg, but replace Lanyards to hold the Wings in place. Front Gate Lanyards 9

10 3/8 NO NEW HARDWARE REQUIRED FOR THIS PAGE 1.12 Remove the Screws securing the Clips to the Trailer Tongue. Remove Screws 1.13 Using a pair of wire cutters, carefully cut the Zip-Tie securing the Wiring Harness to the Trailer. Run the Wiring Harness through the Clips and reconnect the Clips to the Trailer Tongue using the Screws you removed in the previous step. Wiring Harness Replace Screws 10

11 2 FRONT GATE INSTALLATION Hardware shown at 50% actual size HARDWARE REQUIRED BST (x1) Gate Pin PARTS REQUIRED Parts shown at 4% actual size BJD (x1) Front Gate TOOLS REQUIRED Wire Cutters Safety Glasses (1) (1 pair for each person) 11

12 TOOLS AND HARDWARE REQUIRED FOR THIS PAGE BST (x1) 2.1 Set the Front Gate (BJD) on the Tongue, up against the front of the Trailer, and with the locator tabs between the left and right Tongue arms. BJD Locator Tabs Tongue Arms 2.2 Insert the Locking Pin (BST) down through the bracket on the Front Panel and into the hole in the Front Gate to secure the Front Gate in place as shown. BST Front Gate Bracket 12

13 3 CONNECTING THE TRAILER TO THE TOW VEHICLE 3.1 COUPLING THE TRAILER TO THE TOW VEHICLE ball, adjust the position of the tow vehicle. coupler to the hitch ball. horizontal position to lock it in place. CONNECTING CHAINS AND ELECTRICAL CONNECTOR TO TOW VEHICLE 3.2 Connect the Chains and Electrical Adaptor to the Tow Vehicle. WARNING Verify all lights and brakes are working before towing the Trailer. 13