STANDARD BODY ASSEMBLY INSTRUCTION - Caddy
Tools Required (Not
supplied)
2 x 17mm Spanners
1 x 8mm Spanner
1 x 3mm Hexagon Key
1 x 6mm Drill Bit
1 x Torque Wrench
FITTING
INSTRUCTIONS
A
B
C
D
E
F
F1
GH
K
L
1
1
1
1
4
1
1
1
2
2
2
Chassis / Base Panel
Side Panel (right hand)
Side Panel (left hand)
Front Panel
Tail gate
Drawbar (Left hand)
Drawbar (Right hand)
Front Chassis Reinforcing Angle
Drawbar stiffening Angles
Axle Complete
Suspensions Brackets (L & R hand)
M
N
O
OS
P
Q
R
AF
AG
AH
AI
AJ
AK
1
2
2
2
4
2
2
2
1
1
1
4
2
Lighting Baord
Wheels / Tyres
Mudguard
Spray Accessories
Reflective Triangles
Front Corner posts
Rear Corner posts (L & R hand)
Draw Bar Fixing Plates
Coupling
Drawbar Front Brace
Coupling Connection
Amber Reflectors
Front Clear Reflector / Cleats & M5 x 12mm
Hex Screws / nuts
AL
S
W
W1
X
Y
Z
Z1
AB
AC
AD
AE
AS
ST
2
2
40
1
41
14
42
4
6
18
1
8
1
1
Mudguard Brackets
Spring Fasteners & catch plates with
screws
M10 x 20 Bolts
M10 x 40 Bolt /Nyloc Nut/ Flat
washer
M10 Nyloc Nuts
M5 x 25 Hex Screws
M5 x 12 Hex Screws
M6 x 10mm Cap Screws
Mud gaurds
M5 Nyloc Nuts
Coupling Chain & 'D' Shackle
Cable Clips
Skid
Adhesive Silver Tailgate Label
1.
With the aid of the diagram identify all the components in the kit.
2.
Lay the trailer base upside down on a flat surface with the ribs facing upwards.
3.
Loosely Assemble the side panels ( B & C) to the base using M5 x 12 Hex screws (Z) and loosely attach font panel (D) using Cap screws (Z).
4.
Assemble font clear reflector and cleats (AK) using M5 x 12mm screws and nuts. Loosely assemble the front conner posts (Q) and clear reflector (AK) as shown using screws (Z) Then raise
the back of the trailer and attach rear corner posts ® using M5 x 12 Hex head (Z).
5.
NOW TURN THE TRAILER UPSIDE DOWN to ensure that assembly of your trailer your trailer is simple it is important that you keep the fixings in the next few steps as losse as possible until
you are instructed to tighten them.
6.
Loosely attach the suspension mounting brackets (L) to the sides of the trailer as shown in diagram using the M10 x 20 bolts (W) and Nyloc nuts (X).
7.
Loosely attach the Left and Right Hand drawbar (F) to the front of the suspension brackets (L) using drawbar fixing plates (AF) with bolts M10 x 20 (W) and nuts (X). The shorter sides of the
drawbar fixing plates (AF) fixes to the suspension brackets (L)
8.
Loosely attach the coupling connection (AI) and the drawbar front brace (AH) and skid (AS) to the front of the drawbars (F&F1) then attach the coupling (AG) to the coupling connection (AI)
using one bolt M10 x 20 (W), one M10 x 40 (W1) and nut (X). Attach the coupling chain (AD) to the M10 x 40 bolt and secure using the M10 Nyloc nut.
9.
Fit the front chassis reinforcing angle (G) under the lip of the front panel (D), fix through drawbars (F&F1) using bolts (W) and nuts (X)
10.
Loosely attach the drawbar stiffening brackets (H) to the side drawbar (F & F1) and front panel (D) using bolts (W) and nuts (X).
11.
Loosely attach the suspension beams (K) to the suspension bracket (L) using bolts (W) and nuts (X). Note the arms to the suspension unit should lay towards the rear, as shown in diagram.(It is
advisable to to paint the axle with good quality rust protecting paint before fitting. The axle supplied is coated with primer only and may be prone to rust over a period of time.
12.
Before tightening all bolts and screws, ensure that both axles are running in alignment by laying a straight edge along the sides of the hubs. Tighten all the the bolts and screws.
13.
Attach spray suppression (OS) to Mud guards (O) using bolts (Y) and nuts (AO). Attach the mud guards to the trailer using M5 x 25mm Hex screws (Y), repair washers (AB) and nyloc nuts. (Do
not over tighten). Now attach the mud guard brackets (AL) to the trailer.
14.
Attach the wheels to the hubs using the domed head wheel nuts (WN). Ensure that the tyre valve faces outwards and the domed end of the wheel nuts must be against the wheel. Tighten the
wheel nuts
15.
Attach the lighting board as shown in the diagram using M5 x 12mm Hex screws (Z) Feed the cable through the hole in the rear lighting recess and run the front to the trailer using the cable clips
(AE) to secure along the way
16.
Turn the trailer the correct way up. Use caution not to damage the rear end and lights.
17.
Attach the spring fasteners and catch plate (S) to the rear panel and corner posts (R) using M5 x 12 Hex heads. Slide the tailgate onto the hinges attached at the base.
18.
Fit the triangles to inside and outside the tailgate using screws (Y) and nuts (AC). Attach the adhesive silver tailgate label (ST) outside the tailgate. Attach the self-adhesive reflectors to the sides
NOTE: Check all fixings have been tightened. Do this again after first 100 miles and then every 1000 miles thereafter.
The caddy trailer uses taper roller bearings which are pre-greased for assembly and require checking and re-greasing if necessary every 1000 miles. Grease nipples are provided on hub for this purpose
Maximum carrying capacity 640 620kg, 700lbs. Maximum tyre pressure 30psi is recommended for general use.
Summary of Contents for 640t
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