Malone XtraLight MPG525G, Assembly Instructions Manual

Page 1: ...he 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 MPG525 MALONE R MALONE R ...

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: ...mmer Visit us at maloneautoracks com for more fine products and accessories Malone MicroSport Trailer Model MPG460XT Assembly Instructions TM REV 2 MPG525G Malone XtraLight TM Trailer Model MPG525G 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 component...

Page 4: ...800 295 0042 ext 206 technical maloneautoracks com 2 Group 1 Frame Components Bag 11430 Group 2 Axle Spring Components Bag 11432 Visit www maloneautoracks com Replacement Parts for all of your spare part needs ...

Page 5: ...1431 Group 3 Lighting Components Group 5 Coupler Components Bag 11494 Group 3 Lighting Components Bag 11468 MPG460G 1 Installing the ground wire con nector Strip 3 8 of insulation off the COUPLER ASSEMBLY Group 5 Visit www maloneautoracks com Replacement Parts for all of your spare part needs ...

Page 6: ...ars 2 and Brackets 4 Load Bars Support Tubes 4 TONGUE FRAME ASSEMBLY Group 1 1 First we will build the 2 piece tongue The middle of the tongue has symmetrical holes for the joining plates and You can identify the hitch end of the tongue by the 3 holes on the left drivers side for the coupler 2 Align the tongue half s together and insert the wiring harness through both sections of the tongue making...

Page 7: ...rame Fully tighten the rear spring hangers Finger tighten the front spring hangers MALONE R technical maloneautoracks com 800 295 0042 ext 215 5 4 Layout the frame components as shown upside down a The spring bracket mounting holes in the side rails must face up b The tongue mounting holes in the middle of the front two cross members must face up c The MALONE decal is on the rear cross member and ...

Page 8: ...lope containing the manufacturer s certificate of origin MCO and VIN labels aside in a safe place 2 Find the side of the axle with the spring centering holes These holes mate with the spring center stud 4 Run each nut down UNTIL IT NEARLY TOUCHES THE PLATE ONLY DON T FULLY TIGHTEN NOW You may need to wiggle the springs to fit them into the spring brackets in the next step 7 Install the long 1 2 bolt...

Page 9: ...ith valve stems facing out and install and finger tighten the lug nuts MPG525G 800 295 0042 ext 206 technical maloneautoracks com 8 5 Lift the axle spring assembly to the trailer frame and slide the slipper spring ends into the slipper spring brackets Then let the spring eyes down into the front hangers 6 Install the shackle bolts with the nuts to the inside and tighten until firm Do not over tighte...

Page 10: ... through the center hole and the lamp studs through the outer holes Use the nuts provided with the lamp kit 2 Using the holes in the front corners of the frames side rail mount the amber side lights First push the wire leads through the outside holes and the lamp stud through the center hole 3 Secure with the lamp stud nut technical maloneautoracks com 8 800 295 0042 ext 215 MALONE R 4 Starting at...

Page 11: ...it 11 Screw a wire nut down over each until firm Then tuck the wire into a frame clip as shown FENDER ASSEMBLY Group 4 1 Loosely install fender mounting brackets as shown so they can move to fit the fender Use hex bolts with the nuts inside the frame 2 Install and fully tighten fender Use screws and nuts nuts inside fender 3 Fully tighten fender mounting brackets FENDER ASSEMBLY Group 4 6 Next we ll...

Page 12: ... nector Strip 3 8 of insulation off the white ground wire and crimp on the ring connector as shown 2 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 LOAD BAR ASSEMBLY Group 6 1 Use a small hammer or block of wood to install the end plugs into both ends of all four load bar support tubes 2 Install the load bar support tu...

Page 13: ...nd brackets onto the load bar supports Center the load bars and fully tighten all load bar bolts 5 Use a small hammer or block of wood to install the end caps onto the load bars Apply the TIRE AND LOADING Decal and the VIN Decal as shown below onto the driver side of the frame Be sure to clean the frame before applying the decals Your XtraLight Trailer is now complete and ready to register and tit...

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Page 15: ...MALONE R MALONE R Trailer Checklist Maintenance Manual MPG460G MicroSport MPG535G MegaSport MPG525G XtraLight MPG570G Sherpa ...

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Page 17: ...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 18: ... 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 19: ...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 20: ... 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 21: ...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 22: ...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 23: ...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 24: ...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 25: ...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 ...