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Malone MegaSport MPG550LB, Manual

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Malone MegaSport MPG550LB Manual Download Page 1

MPG550LB

MALONE

R

MALONE

R

*

ATTENTION CUSTOMERS

*

Thank you for your recent purchase of a Malone trailer.

Please inspect all parts and hardware bags prior to assembly.

**Set the large red envelope (in the axle box) containing

important documents in a safe spot. 

 If you encounter any missing components please contact us at:

Email:[email protected]

OR

Phone:(207) 774 - 9100 X215

Business Hours: Monday-Friday

9am- 5pm

Thank you from all of us at Malone

Summary of Contents for MegaSport MPG550LB

Page 1: ...ts and hardware bags prior to assembly Set the large red envelope in the axle box containing important documents in a safe spot If you encounter any missing components please contact us at Email techn...

Page 2: ...of 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 inform...

Page 3: ...er Visit us at maloneautoracks com for more ne products and accessories Malone MicroSport Trailer Model MPG460XT Assembly Instructions TM REV 2 MPG550LB Malone MegaSport TM Trailer Model MPG550LB Asse...

Page 4: ...215 technical maloneautoracks com 2 Group 1 Frame Components Group 2 Axle Spring Components Bag 11412 1 Bag 11412 Tongue Frame Main Frame Visit www maloneautoracks com Replacement Parts for all of you...

Page 5: ...echnical 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...

Page 6: ...Group 7 Jack Stand 4 Group 6 Load Bar Components x4 x4 Visit www maloneautoracks com Replacement Parts for all of your spare part needs...

Page 7: ...ain frame on its back to make it easier to install the tongue frame springs and axle Once the springs and axle assembly is installed we will flip the trailer over to complete the assembly 2 With the f...

Page 8: ...attaching the tongue components with the side frame rails first then the tongue down the middle Tighten the side rails beginning at the 4th cross member back going through both the main frame rail and...

Page 9: ...r at the tongue You ll use washers on front 2 cross members utilizing the larger oval holes 6 Begin attaching the tongue components with the side frame rails first then the tongue down the middle Tigh...

Page 10: ...pictured 10 Attach the spring hanger brackets to the frame Right at the end of tongues side rail The U shaped shackle bolt brackets mount to the front and the C shaped slipper brack ets mount to the...

Page 11: ...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 800 295 0042 ext 215 technical maloneautoracks com 9 MALONE R tec...

Page 12: ...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 800 295 0042 ext...

Page 13: ...me tighten the axle plate U bolts evenly until there is a slight bend in the tie plates 9 With 2 people Standing on the side the trailer lift the frame rail member at the corners and flip the trailer...

Page 14: ...loneautoracks com 12 LIGHT ASSEMBLY Group 3 L E D REFERENCE Trailer Wiring Color Code Brown running lights Yellow left turn left brake Green right turn right brake White ground 1 First attach the tail...

Page 15: ...lug in the remaining wiring harness into the connection behind the tongue Looking at the end connections route the GREEN BROWN WHITE wire along the passengers side Route the YELLOW BROWN WHITE along t...

Page 16: ...s Repeat with all remaining lights 8 Use the clips provided to secure the wire to the inside of the frame channel as shown NOTE THESE UNUSED PLUGS ARE FOR AUXILIARY ACCESSORIES LIKE THE MALONE MPG543...

Page 17: ...ck shown below 800 295 0042 ext 215 technical maloneautoracks com 16 MALONE R technical maloneautoracks com 15 800 295 0042 ext 215 FENDER ASSEMBLY Group 4 1 Connect all 4 fender brackets to the fende...

Page 18: ...nstall 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...

Page 19: ...2 ext 215 technical maloneautoracks com 18 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 MALONE R technical maloneaut...

Page 20: ...ngue Don t over tighten and crush the tongue 800 295 0042 ext 215 technical maloneautoracks com 19 5 Install the coupler and coupler handle onto the tongue as shown Then tighten until the coupler firm...

Page 21: ...out of the way during transport It can be ro tated towards the front or rear 800 295 0042 ext 215 technical maloneautoracks com 23 JACK STAND Group 7 8 Go back now and re check that all nuts and bolt...

Page 22: ...MALONE R technical maloneautoracks com 20 800 295 0042 ext 215 FPO x4 x4 Load Bar Components Group 6 NOTE The curved upright supports will not be used for this build not pictured...

Page 23: ...MALONE R technical maloneautoracks com 21 800 295 0042 ext 215...

Page 24: ...MALONE R technical maloneautoracks com 22 800 295 0042 ext 215...

Page 25: ...MALONE R technical maloneautoracks com 23 800 295 0042 ext 215...

Page 26: ...MALONE R technical maloneautoracks com 24 800 295 0042 ext 215...

Page 27: ...ur local DMV office for specific procedures in your State Visit us at maloneautoracks com for more fine products and accessories TM 800 295 0042 ext 215 technical maloneautoracks com 24 MALONE R techn...

Page 28: ......

Page 29: ...MALONE R MALONE R Trailer Checklist Maintenance Manual MPG460G MicroSport MPG535G MegaSport MPG525G XtraLight MPG570G Sherpa...

Page 30: ......

Page 31: ...ad 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 stan...

Page 32: ...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 FRON...

Page 33: ...s 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 R...

Page 34: ...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 insid...

Page 35: ...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 h...

Page 36: ...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 sud...

Page 37: ...er 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...

Page 38: ...uality 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 tra...

Page 39: ...n 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 replaci...

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