Malone MPG460XT, Manual

Page 1: ...gs 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 technical maloneautoracks com OR Phone 207 774 9100 X215 Business Hours Monday Friday 9am 5pm Thank you from all of us at Malone ...

Page 2: ...purchase You can also mail this letter back to the address at the bottom Online www maloneautoracks com Email Technical 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 ch...

Page 3: ...er Visit us at maloneautoracks com for more fine products and accessories Malone MicroSport Trailer Model MPG460XT Assembly Instructions TM REV 2 MPG460XT Malone MicroSport TM 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 componen...

Page 4: ...technical maloneautoracks com 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 ...

Page 5: ... E D REFERENCE Trailer Wiring Color Code Brown running lights Yellow left turn left brake Green right turn right brake White ground 800 295 0042 ext 206 technical maloneautoracks com 3 Group 4 Fender Components Bag 11464 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 ...

Page 6: ...nce 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 technical maloneautoracks com 4 FRAME ASSEMBLY Group 1 1 We assemble the frame u...

Page 7: ...rs 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 tech...

Page 8: ...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 shor...

Page 9: ...ers 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 ...

Page 10: ...nd 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 ...

Page 11: ...ots 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 ...

Page 12: ...s 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...

Page 13: ... 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 technical maloneautoracks com 11 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...

Page 14: ...s the hitch pin through and install the ring clip MPG460XT 800 295 0042 ext 206 technical maloneautoracks com 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...

Page 15: ...r 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 ...

Page 16: ...nnector 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 technical maloneautoracks com 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 passen...

Page 17: ...onnector 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...

Page 18: ...r 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 technical maloneautoracks com 16 800 295 0042 ext 215 MALONE R ...

Page 19: ... 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 MALONE R technical maloneautoracks com 800 295 0042 ext 215 17 ...

Page 20: ...toracks com 19 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 technical maloneautoracks com 18 800 295 0042 ext 215 MALONE R ...

Page 21: ...as shown Then tighten until the coupler firmly grips the tongue Don t over tighten and crush the tongue 5 Install the coupler and coupler handle onto the tongue as shown Then tighten until the coupler firmly grips the tongue Don t over tighten and crush the tongue NOTE OVER TIGHTENING WILL PREVENT THE COUPLER LATCH FROM FUNCTIONING PROPERLY 2 Place the skid and chain assembly under the tongue and i...

Page 22: ... the second support tube 48 inches forward Measure 48 inches on both sides of the trailer to be sure the load bar is on straight and centered then tighten the U bolts 800 295 0042 ext 206 technical maloneautoracks com 21 MPG460XT LOAD BAR ASSEMBLY Group 6 technical maloneautoracks com 20 800 295 0042 ext 215 MALONE R X4 ...

Page 23: ...ical maloneautoracks com 22 3 Use your hammer and carefully pound the end plugs into the ends of the support tubes 4 Slip the load bar brackets over the load bars as shown and loosely install the two small carriage bolts nuts through each bracket trapping the load bars inside the brackets MPG460XT ...

Page 24: ...e frame before applying the decals DECALS REGISTRATION TITLING technical maloneautoracks com 22 800 295 0042 ext 215 MALONE R MPG460XT 6 Center the load bars to the trailer then tighten all 12 bracket bolts 7 Go back now and recheck that all nuts and bolts on the ENTIRE trailer are securely tightened Your MicroSport Trailer is now complete and ready to register and title Contact your local DMV offi...

Page 25: ... from the frame harness and tuck the harness into the rear of the tongue 2 Remove the hitch pin from the frame 3 Slide the tongue into the frame until the end of the tongue aligns with the retainer bracket as shown to the right 4 Install the hitch pin and retainer ring When retracted the trailer may stood up on end either against a wall tree or post for reduced footprint storage as shown When stan...

Page 26: ......

Page 27: ...MALONE R MALONE R Trailer Checklist Maintenance Manual MPG460G MicroSport MPG535G MegaSport MPG525G XtraLight MPG570G Sherpa ...

Page 28: ......

Page 29: ...oad carrying capacity Tires are properly inflated All trailer lighting is working properly Additional checks you can do Conduct routine maintenance by having a friend or family member occasionally stand behind your trailer and make sure the brake lights taillights and turn signals are in good working order As with your boat a thorough freshwater wash down of your trailer after each use will extend...

Page 30: ... 23 LBS 25 LBS 63 LBS 70 LBS CROSSBAR SPREAD 47 FIXED 44 63 68 FIXED 71 FIXED 30 BASE G XT 31 22 AND 58 LOWBED 25 AND 56 LOWBED FRAME TONGUE MATERIAL FRAME CONSTRUCTION 2pc DESIGN 2 x3 x96 89 FROM FRONT OF FRAME TO BALL CROSSBAR CONSTRUCTION LIGHTING MALONE TRAILER SPECIFICATIONS Revised 8 2 18 By MP 325 LBS 2 BALL HEIGHT FROM GROUND 15 5 16 16 375 lbs 159 LBS WEIGHT WITHOUT ACCESSORIES LOAD CAPIC...

Page 31: ...gs are failing and must be replaced 4 Wipe excess from front and re install the dust cap Procedure for hubs with out a zerk fitting i Prepare a disposable container for the old grease to fall into ii Remove dust cap cotter pin crown nut washer Pull hub off spindle iii Inspect inside the hub where the cups seat and the spindle for scoring pitting bending dents thread or other damage iv With the hub...

Page 32: ... spindle 2 Use a hammer and a mild steel bar to drive out old inner cups 3 Use a solvent such as kerosene to clean the hub nut washer and spindle All dirt and old grease must be removed 4 Inspect inside the hub where the cups seat and the spindle for scoring pitting bending dents thread or other damage Pay close attention to the raised rear surface of the spindle where the grease seal grips If it ...

Page 33: ...b full of grease 12 Install the packed outer bearing and cup then pack more grease into any voids and in stall the washer and nut 13 While turning the hub use a 12 wrench to tighten the nut until the hub begins to bind indicating that all the bearing parts are sealed properly 14 Back off the nut about turn as needed until you have between 001 to 007 of end play 15 Warning Failure to back off the n...

Page 34: ...e driver needs to assess the situation to determine the proper course of action Here is a list of dos and don ts to think about Good Towing Practice Gradually reduce speed Steady the steering wheel sudden turns can cause more sway Pull to side of roadway if needed NOT Good Towing Practice Do not slam on the brakes jackknifing could occur Do not attempt to steer out of a sway situation Do not incre...

Page 35: ...ler Lights Note Wiring colors are the same from incandescent lights and LED light kits Yellow driver s side turn signal Green Passenger side turn signal Brown x 2 running lights both sides White common ground Trailer Wiring Assembly Incandescent wiring LED wiring Our trailers use a standard flat four pin connection at the harness Some larger vehicles are outfitted with a round 7 pin configuration ...

Page 36: ...quality electrical contact cleaner and a fine wire brush 3 Check the Ground Most problems occur because of a bad ground If your using incandescent lights they should be grounded at the front of the trailer along the metal frame should be a white wire Double check and clean all connections with sandpaper If the ground screw is corroded it should be replaced LED lights on the hand use the vehicle as...

Page 37: ...on or entity during the five year warranty period Subject to the limitations and exclusions described in this warranty Malone will remedy defects in materials and or workmanship by repairing or replacing at its option a defective product without charge for parts or labor Malone may elect at its option not to repair or replace a defective product but rather issue to the original retail purchaser a ...