Harbor Freight 1090 Lb Capacity 40 1 2 In X 48 Utility Trailer Product Manual

Harbor-Freight-90153-Owner-S-Manual harbor-freight-90153-owner-s-manual

90154 90153

2015-05-27

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Owner’s Manual & Safety Instructions
Save This Manual Keep this manual for the safety warnings and precautions, assembly, operating,

inspection, maintenance and cleaning procedures. Write the product’s serial number in the back of the manual
near the assembly diagram (or month and year of purchase if product has no number). Keep this manual and
the receipt in a safe and dry place for future reference.

ITEM 90153

WARNING!
IMPORTANT INFORMATION
This trailer’s Hitch Coupler MUST be
properly secured to the hitch ball of the towing
vehicle. After assembly and attachment, pull
up and down on the Hitch Coupler to make
sure the hitch ball is fitting snugly in the Hitch
Coupler. There must be no play between the
hitch ball and the Hitch Coupler. If there is
play, tighten the Adjustment Nut until no play is
present. If the Adjustment Nut is too tight, the
Handle will not lock. Carefully read and follow the complete instructions in this manual
BEFORE setup or use.

If the coupler is not secured
properly, the ball could come loose
while the trailer is in motion, possibly
causing property damage, SERIOUS
PERSONAL INJURY, or DEATH.

REV 12j

Visit our website at: http://www.harborfreight.com
Email our technical support at: tech@harborfreight.com

When unpacking, make sure that the product is intact
and undamaged. If any parts are missing or broken,
please call 1-800-444-3353 as soon as possible.
Copyright© 2003 by Harbor Freight Tools®. All rights reserved.
No portion of this manual or any artwork contained herein may be reproduced in
any shape or form without the express written consent of Harbor Freight Tools.
Diagrams within this manual may not be drawn proportionally. Due to continuing
improvements, actual product may differ slightly from the product described herein.
Tools required for assembly and service may not be included.

Read this material before using this product.
Failure to do so can result in serious injury.
SAVE THIS MANUAL.

CONTENTS
SPECIFICATIONS..................................................................................... 3
GENERAL SAFETY WARNINGS AND PRECAUTIONS......................... 3
SPECIFIC PRODUCT WARNINGS AND PRECAUTIONS...................... 4
ASSEMBLY INSTRUCTIONS................................................................... 6
OPERATING INSTRUCTIONS................................................................ 15
TIRE INFORMATION............................................................................... 16
Tire Terminology Glossary...................................................................................16
Tire Markings.........................................................................................................17
Tire Inflation and Load Limit................................................................................18

TIRE CARE.............................................................................................. 19
Checking Tire Pressure........................................................................................19
Steps for Maintaining Proper Tire Pressure.......................................................19
Tire Size.................................................................................................................20
Tire Tread...............................................................................................................20
Tire Rotation..........................................................................................................20
Tire Balance and Alignment.................................................................................20
Tire Repair.............................................................................................................20

VEHICLE LOAD LIMIT............................................................................ 21
Steps for Determining Correct Load Limit..........................................................21

INSPECTION, MAINTENANCE, AND CLEANING................................. 21
PARTS LIST AND DIAGRAMS................................................................ 22
Parts List................................................................................................................22
Assembly Diagram................................................................................................23
Wiring Diagram......................................................................................................24

Item 90153

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PAGE 2

SPECIFICATIONS
Maximum Payload Capacity
GVWR
Net Weight
Rim Size
Tire Size
Tire Pressure
Hitch Ball
Bed Frame
Axle Clearance
Tongue Height
Safety Chain
Lights & Wiring

1,090 lb.
1,250 lb.
151 lb.
4.80/4.00 - 12″ w/4 Lug Nut Pattern
4.80 x 12, 4PR
60 PSI, cold
1-7/8″, Class I
40-1/2″ x 48″
7″
12-1/2″
1″ Link (Welded)
7/32″ Diameter x 42″ L w/S Hooks
12 VDC / DOT Approved

GENERAL SAFETY WARNINGS AND PRECAUTIONS
1.

KEEP WORK AREA CLEAN AND DRY. Cluttered, damp, or wet work areas invite
injuries.

KEEP CHILDREN AWAY FROM WORK AREA. Do not allow children to handle
this product.

STORE IDLE EQUIPMENT. When not in use, tools and equipment should be stored
in a dry location to inhibit rust. Always lock up tools and equipment, and keep out
of reach of children.

DO NOT USE THIS PRODUCT IF UNDER THE INFLUENCE OF ALCOHOL OR
DRUGS. Read warning labels on prescriptions to determine if your judgement or
reflexes are impaired while taking drugs. If there is any doubt, do not attempt to
use this product.

USE EYE PROTECTION. Wear ANSI approved safety impact eye goggles when
assembling this product. ANSI approved safety impact eye goggles are available
from Harbor Freight Tools.

DRESS SAFELY. Do not wear loose clothing or jewelry, as they can become caught
in moving parts. Wear a protective hair covering to prevent long hair from becoming
caught in moving parts. If wearing a long-sleeve shirt, roll sleeves up above elbows.

DO NOT OVERREACH. Keep proper footing and balance at all times to prevent
tripping, falling, back injury, etc.

INDUSTRIAL APPLICATIONS MUST FOLLOW OSHA REQUIREMENTS.

STAY ALERT. Watch what you are doing at all times. Use common sense. Do not
use this product when you are tired or distracted from the job at hand.

Item 90153

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PAGE 3

10.

CHECK FOR DAMAGED PARTS. Before using this product, carefully check that
it will operate properly and perform its intended function. Check for damaged parts
and any other conditions that may affect the operation of this product. Replace or
repair damaged or worn parts immediately.

11.

REPLACEMENT PARTS AND ACCESSORIES: When servicing, use only identical
replacement parts. Only use accessories intended for use with this product.
Approved accessories are available from Harbor Freight Tools.

12.

MAINTAIN THIS PRODUCT WITH CARE. Keep this product clean and dry for
better and safer performance.

13.

MAINTENANCE: For your safety, service and maintenance should be performed
regularly by a qualified technician.

14.

USE THE RIGHT TOOL FOR THE JOB. Do not attempt to force small equipment
to do the work of larger industrial equipment. There are certain applications for
which this equipment was designed. It will do the job better and more safely at the
capacity for which it was intended. Do not modify this equipment, and do not use
this equipment for a purpose for which it was not intended.

15.

WARNING: The warnings, precautions, and instructions discussed in this manual
cannot cover all possible conditions and situations that may occur. The operator
must understand that common sense and caution are factors, which cannot be built
into this product, but must be supplied by the operator.

SPECIFIC PRODUCT WARNINGS AND PRECAUTIONS
1.

TO AVOID PERSONAL INJURY AND/OR PROPERTY DAMAGE, DO NOT
EXCEED THE TRAILER’S MAXIMUM CAPACITY PAYLOAD OF 1,090 LBS.

BEFORE EACH USE, ALWAYS EXAMINE THE TRAILER FOR PROPER TIRE (16)
AIR PRESSURE, DAMAGED TAIL LIGHTS (29, 29A), DAMAGED SIDE RUNNING
LIGHTS (30), LOOSE BOLTS AND NUTS, STRUCTURAL CRACKS, BENDS, AND
ANY OTHER CONDITION THAT MAY AFFECT ITS SAFE OPERATION. Do not
use the Trailer even if minor damage appears.

NEVER ALLOW ADULTS, CHILDREN, OR PETS TO RIDE IN THE TRAILER.

BEFORE EACH USE, ALWAYS ATTACH THE SAFETY CHAIN (25) OF THE
TRAILER TO THE TOWING VEHICLE. Make sure the Safety Chain is attached
to the towing vehicle with the same length for each side. Do not allow the Safety
Chain to drag on the ground.

ALWAYS CHECK TO MAKE SURE THE PAYLOAD BEING TRANSPORTED IS
PROPERLY AND SAFELY SECURED IN THE TRAILER. Load the Trailer evenly
from side to side with 60% of the load forward of the Axle (12).

MAKE SURE THE TOWING VEHICLE IS CAPABLE OF TOWING THE TRAILER
AND ITS PAYLOAD. Make sure the hitch on the towing vehicle is capable of towing

Item 90153

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PAGE 4

the Trailer and its payload. The towing capacity of the hitch is typically stamped
on the hitch drawbar.
7.

MAKE SURE THE COUPLER (23) AND THE VEHICLE’S BALL HITCH (not
included) ARE OF EQUAL MATING SIZE (1-7/8″) AND ARE RATED EQUAL
TO OR GREATER THAN THE WEIGHT OF THE TRAILER AND ITS PAYLOAD.

DO NOT EXCEED 45 MILES PER HOUR WHEN TOWING THE TRAILER.
Excess speed is a major cause of vehicle-trailer accidents.

THE TAIL LIGHT BULBS SUPPLIED WITH THIS TRAILER ARE FOR A 12 VOLT
DC ELECTRICAL SYSTEM ONLY. Do not attempt to power the Light Bulbs with
any other type or voltage electrical current.

10.

WHENEVER POSSIBLE, PARK THE TRAILER ON A FLAT, LEVEL, PAVED,
SURFACE AND CHOCK BOTH TIRES TO KEEP THE TRAILER FROM
ACCIDENTLY MOVING.

11.

TRAILER LICENSING NOTICE: Some states may consider this Trailer a vehicle
requiring registration, licensing, and titling. Check with your State Department of
Motor Vehicles for information and guidance on registering, licensing, and titling
the Trailer.

12.

MAINTAIN LABELS AND NAMEPLATES ON THE TRAILER. These carry
important information. If unreadable or missing, contact Harbor Freight Tools for
a replacement.

13.

REPORTING SAFETY DEFECTS: If you believe your vehicle has a defect which
could cause a crash or could cause injury or death, you should immediately inform
the National Highway Traffic Safety Administration (NHTSA) in addition to notifying
the manufacturer, Changzhou Nanxiashu Tool Company. If NHTSA receives similar
complaints, it may open an investigation, and if it finds that a safety defect exists in
a group of vehicles, it may order a recall and remedy campaign. However, NHTSA
cannot become involved in individual problems between you, Harbor Freight Tools,
or the manufacturer. To contact NHTSA, you may either call the Auto Safety Hotline
toll-free at 1-800-424-9393 or 202-366-0123 or write NHTSA, U.S. Department,
400 7th Street SW NSA-11, Washington, D.C. 20590. You may also obtain other
information about motor vehicle safety from the Hotline.

Item 90153

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PAGE 5

DON’T TIGHTEN YET!

TO MAKE ASSEMBLY EASIER, wait until assembly is
complete and all hardware is in place before tightening
any nut or bolt. Leave hardware snug until then.

ASSEMBLY INSTRUCTIONS
Note: For additional references to the parts listed on the following pages, refer to the
Assembly Diagram near the end of this manual. Be sure to read the Bearing
Packing instructions on the last page of this manual.
HEX BOLT
(1)
LEFT
SIDE RAIL
(5)

CROSS
MEMBER
(4)

REAR
1.

FRONT

CROSS
MEMBER
(4)
CROSS
MEMBER
(4)

NYLON NUT (3)
(NOT SHOWN)

RIGHT
SIDE RAIL
(5A)

FIGURE A

Lay out three Cross Members (4), the Right Side Rail (5A), and the Left Side Rail
(5). Then assemble the parts, using Hex Bolts (1) and Nylon Nuts (3).
(See Figure A.)

Item 90153

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PAGE 6

DON’T TIGHTEN YET!

TO MAKE ASSEMBLY EASIER, wait until assembly is
complete and all hardware is in place before tightening
any nut or bolt. Leave hardware snug until then.

TOW BAR
(6)

FRONT

HEX
BOLT
(1)

REAR

SPRING SIDE PLATE (8)

FIGURE B

NYLON NUT (3)
(NOT SHOWN)

SPRING
HANGER
(7)

Turn the frame assembly upside down. Attach the Towbar (6) to the frame assembly,
using Hex Bolts (1) and Nylon Nuts (3). NOTE: Observe the direction in which the
Hex Bolts are inserted. (See Figure B.)

Attach two of the Spring Hangers (7) to the front portions of the Right Side Rail
(5A) and the Left Side Rail (5), using Hex Bolts (1) and Nylon Nuts (3). Then attach
the remaining two Spring Hangers, each with a Spring Side Plate (8), to the rear
portions of the Right Side Rail (5A) and the Left Side Rail (5), using Hex Bolts (1)
and Nylon Nuts (3). (See Figure B.)

Item 90153

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PAGE 7

DON’T TIGHTEN YET!

TO MAKE ASSEMBLY EASIER, wait until assembly is
complete and all hardware is in place before tightening
any nut or bolt. Leave hardware snug until then.

REAR

U-BOLT (13)
AXLE (12)
NUT
(11)

LEFT SIDE RAIL (5)

SLIPPER SPRING (9)

NUT (11)
SPRING HANGER (7)

SPRING
PLATE
(14)

COTTER PIN (33)
HEX BOLT (10)
COTTER PIN (33)
HEX BOLT (10)

FRONT

NYLON NUT (3)

FIGURE C

Place the Slipper Springs (9) in the Spring Hangers (7). Secure the Slipper Springs
to the Spring Hangers, using Bolts (10) and Nuts (11). Then, insert a Cotter Pin
(33) through the hole in the end of the Bolts and spread it. (See Figure C.)

Place the Axle (12) on top of the Slipper Springs (9). Position a Spring Plate (14)
under the Slipper Springs. Place two U-Bolts (13) over each end of the Axle and
each Slipper Spring. Then insert the U-Bolts through the holes in the Spring Plates
and secure the Spring assembly, using Nylon Nuts (3). (See Figure C.)

Attach the Grease Fitting (35) to the Hub (15). NOTE: Every 2,000 to 3,000 miles
of use, make sure to lubricate the Hub assembly with a heavy duty bearing grease.
(See Figure D, next page.)

Carefully slide the Hubs (15) over the Spindles at each end of the Axle (12). Follow
the Bearing Packing Instructions as explained on the last page of this manual.
Insert the Bearing (18) and a 3/4″ Flat Washer (19) on the Spindles. Screw a
Castle Nut (20) tightly onto each Spindle. Then back the Castle Nuts off slightly so
that the Hubs (15) can just move freely. (See Figure D.)

Item 90153

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PAGE 8

DON’T TIGHTEN YET!

TO MAKE ASSEMBLY EASIER, wait until assembly is complete
and all hardware is in place before tightening any nut or bolt,
except wheel lugs. Leave hardware snug until then.

COTTER PIN (21)

AXLE
(12)

SPINDLE
GREASE
FITTING
(35)
HUB
(15)

LUG NUT
(17)

3/4″ WASHER
(19)
CASTLE NUT
(20)

TIRE (16)

FIGURE D

LUG NUT (17)

BEARING (18)

DUST CAP
(22)

Place a Tire (16) on each Hub (15). Secure the Tires to the Hubs, using four Lug
Nuts (17) per Tire. NOTE: Make sure to tighten (torque) the Lug Nuts to at least
90 ft-lb. (See Figure D.)

Insert a Cotter Pin (21) through the hole at the end of each Spindle of the Axle (12)
and spread the Cotter Pin. (See Figure D.)

10.

Press each Dust Cap (22) onto each Hub (15). (See Figure D.)

11.

With assistance, turn the Trailer over so that its
Tires (16) are on the floor/ground surface.

12.

Attach the Coupler (23) to the Towbar (6), using Bolts (24) and Nylon Nuts (3). Lock
the Coupler Trigger with the Safety Pin (37). Then, insert the R-Pin (36) through the
hole in the Safety Pin to secure the Safety Pin in place. (See Figure E, next page.)

13.

To attach the Safety Chain (25) to the Coupler (23), insert a Hex Bolt (1) through
the center link of the Chain. Then, use a Nylon Nut (3) to secure the Safety Chain
to the Coupler. NOTE: Make sure the Safety Chain is the same length on each
side. (See Figure E.)

14.

Attach the Tail Light Brackets (27) to the Right Side Rail (5A) and Left Side Rail (5),
using Hex Bolts (1) and Nylon Nuts (3). (See Figure E.)

15.

Attach the License Plate Bracket (28) and Left Tail Light (29) to the Left Side Rail (5),
using Hex Bolts (1) and Nylon Nuts (3). (See Figure E.)

Item 90153

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PAGE 9

LEFT
SIDE RAIL
(5)

COUPLER
(23)
TOW BAR

R-PIN (36)
SAFETY PIN (37)

(6)

BOLT (24)
NUT (3)

LICENSE PLATE
BRACKET
(28)

SAFETY CHAIN (25)
RIGHT
SIDE RAIL
(5A)

LEFT
TAIL LIGHT
(29)

SIDE RUNNING LIGHT
(30)

HEX BOLT (1)
NYLON NUT (3)

RIGHT
TAIL LIGHT
(29A)

FIGURE E

SELF TAPPING SCREW
(31)

TAIL LIGHT
BRACKET
(27)

HEX BOLT (1)
NYLON NUT (3)

FENDER (34)

16.

Attach the Right Tail Light (29A) to the Right Side Rail (5A), using Hex Bolts (1) and
Nylon Nuts (3). (See Figure E.)

17.

Remove the Lens from a Side Running Light (30). Insert the Wire Lead of the
Side Running Light through the center hole of the Right Side Rail (5A). Attach
the Side Running Light to the Right Side Rail, using the Self Tapping Screws (31).
Then, reattach the Lens to the Side Running Light. Repeat this Step for the remaining
Side Running Light and the Left Side Rail (5). (See Figure E.)

18.

Attach a Fender (34) to the Right Side Rail (5A) and Left Side Rail (5), using Hex
Bolts (1) and Nylon Nuts (3). (See Figure E.)

TIGHTEN ALL HARDWARE!

Now that frame is completely assembled, retrace all assembly steps
and make sure that all hardware is properly wrench‑tightened.
Also, tighten lug nuts/lug bolts to 90 ft-lb.
Item 90153

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PAGE 10

WHITE (GROUND)
WIRE CLIP
YELLOW

GREEN

WIRE FROM
SIDE RUNNING
LIGHT (30)

WIRE FROM
SIDE RUNNING
LIGHT (30)
BROWN

BROWN

LEFT
SIDE RAIL
(5)

RIGHT
SIDE RAIL
(5A)

LEFT
TAIL LIGHT
(29)

RIGHT
TAIL LIGHT
(29A)

BROWN

BROWN
YELLOW

GREEN

FIGURE F
19.

To install the Wiring Harness on the Trailer, use a Self Tapping Screw (31) to attach
the White Ground Wire located at the Plug end of the Wiring Harness to the small
mounting hole in the Towbar (6). (See Figure F.)

20.

Leave about 18″ of wire beyond the Coupler (23), and run the Wiring Harness along
the inside of the Towbar (6) to the front Cross Member (4). Then, split the Yellow/
Brown Wires from the Green/Brown Wires. (See Figure F.)

21.

Run the Yellow/Brown Wires along the inside of the front Cross Member (4) to the
Side Running Light (30) located on the Left Side Rail (5). Then, run the Green/
Brown Wires along the inside of the front Cross Member (4) to the other Side
Running Light located on the Right Side Rail (5A). (See Figure F.)

22.

Connect the Wire Lead from the two Side Running Lights (30) to the Brown Wire
on each side of the Trailer. Then, insert Wire Clips along the entire length of the
Side Rails of the Trailer to hold down the Wiring Harness. (See Figure F.)

23.

Run the Yellow/Brown Wires to the Left Tail Light (29). Strip the ends of the Wires
about 3/4″. Connect the Yellow Wire to the Red Wire of the Left Tail Light. Then,
connect the Brown Wire to the two Black Wires of the Left Tail Light.
(See Figure F.)

24.

Run the Green/Brown Wires to the Right Tail Light (29A). Strip the ends of the
Wires about 3/4″. Connect the Green Wire to the Red Wire of the Right Tail Light.
Then, connect the Brown Wire to the two Black Wires of the Right Tail Light.
(See Figure F.)

25.

NOTE: It is recommended that only a qualified technician perform the electrical
service that may be needed to enable your particular make/model vehicle to power
the Trailer’s 12 volt DC lighting system.

Item 90153

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PAGE 11

3/4″ THICK
PLYWOOD

MEASURE WIDTH
& LENGTH OF
TRAILER FRAME.

3/8″ DIA.
HOLE

CUT PLYWOOD TO
MATCH WIDTH &
LENGTH OF TRAILER
FRAME.

FIGURE G

3/8″ DIA.
HOLE

26.

To attach a bed (not included) to the frame of the Trailer, you will need the following
materials and parts:
a. Qty. 1: 3/4″ thick Plywood (not included).
b. Qty. 12: 3/8″ x 1-1/2″ Cross Head Bolts (not included).
c. Qty. 12: 3/8″ Flat Washers (not included).
d. Qty. 12: 3/8″ Spring Washers (not included).
e. Qty. 12: 3/8″ Hex Nuts (not included).

27.

Carefully measure the width and length of the Trailer frame. Then, cut the 3/4″ the
same dimensions as the Trailer Frame. (See Figure G.)

28.

Drill three evenly spaced, 3/8″ diameter, holes in the inner flange of each side of
the Trailer. Then, drill three corresponding, 3/8″ diameter, holes in each side of the
plywood. (See Figure G.)

3/8″ X 1-1/2″ CROSS HEAD BOLT
3/8″ FLAT WASHER
3/4″ THICK PLYWOOD

FIGURE H

3/8″ SPRING WASHER
3/8″ HEX BOLT

29.

With assistance, place the 3/4″ plywood on the Trailer frame and align the predrilled
3/8″ holes in the plywood with the pre-drilled 3/8″ holes in the Trailer frame.
(See Figure H.)

30.

Secure the 3/4″ plywood to the Trailer frame, using twelve 3/8″ x 1-1/2″ Cross Head
Bolts, twelve 3/8″ Flat Washers, twelve 3/8″ Spring Washers, and twelve 3/8″ Hex
Nuts (none included). (See Figure H.)

Item 90153

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PAGE 12

31.

To attach rails (not included) to the Trailer, you will need the following materials
and parts:
a. Qty. 4:

1″ x 4″ x 46″ lumber (not included).

b. Qty. 4:

1″ x 4″ x 37″ lumber (not included).

c. Qty. 8:

1″ x 4″ x 12″ lumber (not included).

d. Qty. 8:

2″ x 2″ x 3-1/2″ Steel Angle (not included).

e. Qty. 32: 3/8″ x 1-3/4″ Hex Bolt (not included).
f. Qty. 32: 3/8″ x 2-3/8″ Hex Bolt (not included).
g. Qty. 64: 3/8″ Spring Washer (not included).
h. Qty. 64: 3/8″ Flat Washer (not included).
i. Qty. 64: 3/8″ Hex Nut (not included).
STAKE

3-1/2″

1-1/2″

12″
3-1/2″

FRONT END/BACK END RAIL

1-1/2″

37″
1-1/2″

SIDE RAIL

3-1/2″

46″
3-1/2″

STEEL ANGLE
FIGURE I

2″

32.

Cut the Stakes, Front End Rails, Back End Rails, and Side Rails to the sizes indicated
in the illustration. (See Figure I.)

33.

Drill 3/8″ holes through the Stakes as indicated in the illustration. (See Figure I.)

Item 90153

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PAGE 13

FRONT
END RAIL

STEEL
ANGLE

STAKE

BACK
END RAIL
3/8″ X 2-3/8″ HEX BOLT
3/8″ FLAT WASHER
3/8″ SPRING WASHER
3/8″ HEX NUT

3/8″ X 1-3/4″ HEX BOLT
3/8″ FLAT WASHER
3/8″ SPRING WASHER
3/8″ HEX NUT

FIGURE J

34.

To determine where to drill 3/8″ holes in the Front End Rails and Back End Rails,
place the eight pre-drilled Stakes in the eight Stake Slots of the Trailer and mark
the Front/Back End Rails with a pencil. (See Figure J.)

35.

Attach the four Side Rails and Front/Back Rails to the Stakes, using the 3/8″ x 2-3/8″
Hex Bolts, 3/8″ Flat Washers, 3/8″ Spring Washers, and 3/8″ Hex Nuts.
(See Figure J.)

36.

Attach the Steel Angles to the Side Rails and Front/Back Rails, using the 3/8″ x
1-3/4″ Hex Bolts, 3/8″ Flat Washers, 3/8″ Spring Washers, and 3/8″ Hex Nuts.
(See Figure J.)

Item 90153

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PAGE 14

OPERATING INSTRUCTIONS

CAUTION

Only use a 1-7/8″ ball hitch (not included) on the
towing vehicle.

NOTE: To reduce friction between the hitch ball and
Coupler (23), apply a layer of heavyweight grease
over the hitch ball.

Temporarily remove the ″R″ Pin (36) and Safety Pin (37). Then, pull up on the Trigger and lift
up on the Handle. (See Figure K.)

Care must be taken when backing up
the Trailer; only back up the trailer on a
straight path. If the Trailer is allowed to turn
off the straight path while backing up, the Trailer
could jackknife, causing severe damage to the
trailer and to the towing vehicle.

TRIGGER
“R” PIN (36)

HANDLE
SAFETY PIN (37)

ADJUSTMENT
NUT

COUPLER (23)
HITCH BALL
(NOT INCLUDED)

SAFETY
CHAIN
(25)

FIGURE K
4.

With assistance, place the Coupler (23) over the vehicle’s hitch ball and pull back on the
Trigger and push down on the Handle until the Trigger locks in the slot. Pull up and down on
the Coupler to make sure the hitch ball is fitting snugly in the Coupler. There should be no
play between the hitch ball and Coupler.
IMPORTANT - If there is play, tighten the Adjustment Nut until no play is present:
After unlocking the Handle, the Nut retaining plate (holding the adjusting nut in place)
needs to be pressed back while the Nut is tightened. After Nut is tightened, the retaining
plate needs to fit in place against the flats of the Nut to prevent it from moving. This
adjustment should be done by 2 people. If the Adjustment Nut is too tight, the Handle will
not lock.
After the Adjustment Nut is properly adjusted, pull back on the Trigger and push down on the
Handle until the Trigger locks in the slot. Pull up on Handle firmly to make sure the Trigger
is locked in place and the Handle cannot move. Replace the Safety Pin and ″R″ Pin. (See
Figure K.)

Make sure to attach each side of the Safety Chain (25) equally to the towing vehicle’s rear
bumper or frame. (See Figure K.)

Connect the Tail Light Wiring Assembly to the towing vehicle’s 12 Volt DC system. NOTE:
Make sure to consult the operator’s manual of the towing vehicle for proper connection
instructions.

When towing the Trailer over long distances stop and check the tightness of all connections,
Side Running Lights (30), and Tail Lights (29, 29A) at least every 100 miles.

Carry emergency flares, and fire extinguisher, if required for operation in your state. Carry
extra bulbs and fuses if towing the Trailer at night over long distances.

Item 90153

For technical questions, please call 1-800-444-3353.

PAGE 15

TIRE INFORMATION
Tire Terminology Glossary
• Accessory weight means- the combined weight of automatic transmission, power steering, power
brakes, power windows, power seats, radio, and heater, to the extent that these items are available as
factory-installed equipment.
• Carcass means- the tire structure except for the tread which provides the major portion of the tire’s
capability to deflect in response to the vertical loads and tractive forces that the tire transmits from the
roadway to the non-pneumatic rim, the wheel center member, or the vehicle and which attaches to the
vehicle or attaches, either integrally or separably, to the wheel center member or non-pneumatic rim.
• Carcass separation means- the pulling away of the carcass from the non-pneumatic rim or wheel
center member.
• Chunking means- the breaking away of pieces of the carcass or tread.
• Cracking means- any parting within the carcass, tread, or any components that connect the tire to the
wheel center member.
• Curb weight means- the weight of a motor vehicle with standard equipment including the maximum
capacity of fuel, oil, and coolant, and, if so equipped, air conditioning and additional weight optional engine.
• Load rating means- the maximum load a tire is rated to carry.
• Maximum loaded vehicle weight means- the sum of:
a. Curb weight;
b. Accessory weight;
c. Vehicle capacity weight; and
d. Production options weight.
• Maximum tire width means- the greater of either the linear distance between the exterior edges of the
carcass or the linear distance between the exterior edges of the tread, both being measured parallel to
the rolling axis of the tire.
• Normal occupant weight means- 68 kilograms times the number of occupants.
• Occupant distribution means- distribution of occupants in a vehicle.
• Production options weight means- the combined weight of those installed regular production options
weighing over 2.3 kilograms in excess of those standard items which they replace, not previously
considered in curb weight or accessory weight, including heavy duty brakes, ride levelers, roof rack,
heavy duty battery, and special trim.
• Tread means- that portion of the tire that comes in contact with the road.
• Tread separation means- pulling away of the tread from the carcass.
• Vehicle capacity weight means- the rated cargo and luggage load plus 68 kilograms times the vehicle’s
designated seating capacity.
• Vehicle maximum load on the tire means- that load on an individual tire that is determined by distributing
to each axle its share of the maximum loaded vehicle weight and dividing by two.
• Vehicle normal load on the tire means- that load on an individual tire that is determined by distributing
to each axle its share of the curb weight, accessory weight, and normal occupant weight and dividing by 2.

Item 90153

For technical questions, please call 1-800-444-3353.

PAGE 16

Tire Markings
Inner diameter
in inches
Section width
in inches

Load index and
Speed rating*
European tire
certificate*
U.S. DOT tire
identification
number

Tire ply
composition
and materials
used
Maximum
permissible
inflation
pressure
Maximum
load rating
Trailer
tire

*Information not required by U.S. DOT

• Section width- This number gives the width of the tire in inches. The larger the number, the wider the
tire. (The markings on the example tire diagram show 4.80. The markings on your tire may differ.)
• Inner diameter- This number gives the inner diameter of the tire in inches. This is also the rim diameter
in inches. (The markings on the example tire diagram show 12. The markings on your tire may differ.)
• U.S. DOT tire identification number- This begins with the letters “DOT” and indicates that the tire meets
all federal standards. The next two numbers or letters are the plant code where it was manufactured, and
the last four numbers represent the week and year that the tire was built. For example, the numbers 2107
mean the 21st week of 2007. Any other numbers used are marketing codes used at the manufacturer’s
discretion. This information is used to contact consumers if a tire defect requires a recall.
• Maximum Load Rating- This number indicates the maximum load in kilograms and pounds that can
be carried by the tire.

Item 90153

For technical questions, please call 1-800-444-3353.

PAGE 17

Code
71
72
73
74
75
76
77
78

Pounds
761
783
805
827
853
882
908
937

Code
79
80
81
82
83
84
85
86

Load Index Rating Codes

Pounds
963
992
1,019
1,047
1,074
1,102
1,135
1,168

Code

Pounds

87
88
89
90
91
92
93
94

Code

1,201
1,235
1,279
1,323
1,356
1,389
1,433
1,477

95
96
97
98
99
100
101
102

Pounds

Code

1,521
1,565
1,609
1,653
1,709
1,764
1,819
1,874

103
104
105
106
107
108
109
110

Pounds
1,929
1,984
2,039
2,094
2,149
2,205
2,271
2,337

• Load index- This is a measurement of how much weight each tire can support. See chart above. (The
markings on the example tire diagram show 71. The markings on your tire may differ.) Note: You may
not find this information on all tires because it is not required by law.
• Speed Rating- The speed rating denotes the speed at which a tire is designed to be driven for extended
periods of time. This does not indicate that the vehicle
Tire Speed Rating Codes
or rims can safely reach or maintain that speed. These
Code MPH Code MPH Code MPH
ratings are listed to the right. (The markings on the
F
50
N
87
U
124
example tire diagram show M. The markings on your
G
56
P
94
H
130
J
62
Q
100
V
149
tire may differ.) Note: You may not find this information
K
68
R
106
Z
149
on all tires because it is not required by law.
L

112

168

• Tire Ply Composition and Materials Used- The
M
81
T
118
Y
186
number of plies indicates the number of layers of rubbercoated fabric in the tire. In general, the greater the number of plies, the more weight a tire can support.
Tire manufacturers also must indicate the materials in the tire, which include steel, nylon, polyester,
and others.
• Maximum Permissible Inflation Pressure- This number is the greatest amount of air pressure that
should ever be put in the tire under normal driving conditions.

Tire Inflation and Load Limit

The weight of cargo should never exceed 493 kg or 1,090 lb.
TIRE

SIZE

COLD TIRE PRESSURE

FRONT

4.80/4.00-12

410 kPa, 60 PSI

REAR

NONE

SPARE

NONE

SEE OWNER’S
MANUAL FOR
ADDITIONAL
INFORMATION.

12a

TIRE AND LOADING INFORMATION

MODEL 90153

Tire and Loading Information Placard

Tire and Loading Information Placard Location
The Tire and Loading Information Placard displays the cold tire inflation pressure
and the load limit for this vehicle. See the Tire Care section starting on the following page
for an explanation of tire pressure and see the Vehicle Load Limit section following that
for an explanation of load limit.

Item 90153

For technical questions, please call 1-800-444-3353.

PAGE 18

TIRE CARE
gently pressing on the tire valve stem with
the edge of your tire gauge until you get to
the correct pressure. If the vehicle have
been driven within the past three hours and
the tire pressure is too high on any tires,
then recheck the pressure once the tires
have been allowed to sit motionless for at
least three hours.

Checking Tire Pressure
Note: Underinflated tires can decrease handling,
stopping performance, traction, tire life,
and load-carrying capability, in addition
to causing other negative and hazardous
effects, including tire failure. Overinflated
tires are at greater risk of an impact break,
where the tread and casing break when
striking a hard edge, often opening a huge
gash across the tread. Incorrect inflation
pressure also increases tires wear rate.
Therefore, it is important to keep tires
inflated properly.

If the tire pressure is too low, note the
difference between the measured tire
pressure and the correct tire pressure.
These “missing” pounds of pressure are
what you will need to add.

At a service station, add the missing
pounds of air pressure to each tire that is
underinflated.

• Tires can suddenly lose air if the tire
strikes a pothole, curb, or other object.

Check all the tires to make sure they have
the same air pressure.

• It is usually not possible to determine
underinflation of radial tires by visual
inspection.

If the tires’ pressure was not measured
“cold”, then the pressure should be
rechecked with the tires cold as soon as
possible.

Check all tires’ pressure at least monthly,
due to the following factors:
• Most tires naturally lose air gradually.

This vehicle has 60 PSI recommended
cold tire inflation pressure. The term “cold” in this
manual does not refer to the temperature outside,
but it refers to the fact that a tire that has not been
driven for a period is cooler (and therefore has
lower pressure) than a tire that has been driven
on. Tires heat up while being driven on. To check
(or fill to) a tire’s cold inflation, the tire must have
not been driven for more than a mile or two for at
least three hours. If you check a tires pressure
when it is not “cold”, the pressure will appear
higher than the actual cold tire inflation.

Steps for Maintaining Proper Tire
Pressure
1.

Locate the recommended tire pressure
on the vehicle’s tire information placard,
certification label, or in the owner’s manual.
This trailer has 60 PSI recommended cold
tire inflation pressure.

Measure and record the tire pressure of
all tires.

If the tire pressure is too high in any of the
tires and the tires have not been driven for
at least three hours, slowly release air by
Item 90153

Tire Size
To maintain safety, only purchase new
tires of the same size as the original tires. Look
at the Tire and Loading Information Placard, the
Specifications Chart in this manual, or the sidewall
of the tire being replaced. If you have any doubt
about selecting the correct size, consult a tire
dealer.

Tire Tread
The tire tread provides traction that
prevents your vehicle from slipping, especially if
the road is wet or icy. Tires are unsafe and should
be replaced when the tread is worn down to 1/16″.
Measure tread depth using a tread depth indicator
(not included).

Tire Rotation
Every 5,000 miles the left and right tires
should be switched. This will cause the tires to
wear more evenly and last longer.

For technical questions, please call 1-800-444-3353.

PAGE 19

Tire Balance and Alignment

Tire Repair

The tires need to be balanced to prevent
vibration when driving. This involves attaching
small weights to the rim to offset small differences
in rim and tire weight. The tires also need to be
aligned properly. Alignment is the orientation
of the tires to the road surface and their being
parallel. This helps the tires to wear evenly, and
provide better traction. Both tire balance and
alignment require specialized equipment that is
not provided with this vehicle.

To properly repair a punctured tire, the
hole needs to be properly plugged and patched
from the inside of the tire. Tread punctures can
be repaired if they are not too large. Sidewall
punctures should not be repaired, the tire needs
to be replaced if the sidewall is damaged. Tires
should be removed from the rim to be inspected
before being plugged and patched. A qualified
mechanic should remove the tire from the rim,
perform the repair, and remount the tire.

VEHICLE LOAD LIMIT
Steps for Determining Correct Load Limit
1.

Locate the statement “The weight of cargo should never exceed XXX kilograms or XXX pounds”
on your vehicle’s placard.

That figure equals the available amount of cargo and luggage load capacity.

Determine the combined weight of luggage and cargo being loaded on the vehicle. That weight
may not safely exceed the available cargo and luggage load capacity.

If the trailer’s load exceeds the cargo and luggage load capacity, then the trailer be unsafe
resulting in hazardous effects, such as: Trailer’s tires will not be able to maintain traction
properly, and stopping distance will be increased significantly.

INSPECTION, MAINTENANCE, AND CLEANING
1.

BEFORE EACH USE, inspect the general condition of the Trailer. Check for loose Bolts and
Nuts, misalignment or binding of moving parts, cracked, bent, or broken parts, excessively
worn Safety Chain, damaged Tail Lights/Side Running Lights/Wiring Harness, loose Lug Nuts,
loose Hitch connection, and any other condition that may affect its safe operation. If abnormal
noise or vibration occurs, have the problem corrected before further use. Do not use damaged
equipment.

BEFORE EACH USE, check the Tires for wear and proper inflation (60 PSI).

BEFORE EVERY USE AND AT 500 MILE INTERVALS DURING EVERY TRIP, check and
tighten the Tire Lug Nuts. Torque from 85 to 90 ft-lb.

EVERY 2,000 TO 3,000 MILES OF USE, lubricate the Hub Assemblies with a heavy weight
bearing grease. Follow the Bearing Packing Instructions as explained on the last page
of this manual. After each Hub Assembly is reassembled, tighten the Castle Nut until the
wheel starts spinning with slight resistance. Loosen the Castle Nut about 1/6 turn from this
point. Insert a new Cotter Pin through the Castle Nut and the hole in the axle. Bend the Pin
back, locking it and the Nut in place.

TO CLEAN, use only water and a mild detergent.
Item 90153

For technical questions, please call 1-800-444-3353.

PAGE 20

PARTS LIST AND DIAGRAMS
PLEASE READ THE FOLLOWING CAREFULLY
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND
ASSEMBLY DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER OR DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND
TO THE BUYER THAT HE OR SHE IS QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT,
OR THAT HE OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT. IN FACT,
THE MANUFACTURER AND/OR DISTRIBUTOR EXPRESSLY STATES THAT ALL REPAIRS
AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND LICENSED
TECHNICIANS, AND NOT BY THE BUYER. THE BUYER ASSUMES ALL RISK AND LIABILITY
ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT
PARTS THERETO, OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT
PARTS THERETO.

Note: Some parts are listed and shown for illustration purposes only, and are not available
individually as replacement parts.

Parts List
Part

Description

Qty

Part

Description

Qty

Hex Bolt (10 x 20 mm)

Castle Nut

Nylon Nut (M10)

Cotter Pin (4 mm)

Cross Member

Dust Cap

Left Side Rail

Coupler

Right Side Rail

Bolt (10 x 90 mm)

Tow Bar

Safety Chain

Spring Hanger

Tail Light Bracket

Spring Side Plate

License Plate Bracket

Left Tail Light

Right Tail Light

Slipper Spring

Hex Bolt (14 x 80 mm)

29A

Nut (M14)

Side Running Light

Axle

Self Tapping Screw

U-Bolt (10)

Seal

Spring Plate

Cotter Pin (3 mm)

Hub

Fender

Tire

Grease Fitting

Lug Nut

R-Pin (3 mm)

Bearing

Safety Pin (10 x 25 mm)

Washer (3/4″)

Item 90153

For technical questions, please call 1-800-444-3353.

PAGE 21

Assembly Diagram

23
5
4

28
29

31
30

34
14

29A
27

33
32
13

1: HEX BOLTS (10 X 20 MM) NOT SHOWN.
3: NYLON NUTS (M10) NOT SHOWN.
8: SPRING SIDE PLATES NOT SHOWN.
10: HEX BOLTS (14 X 80 MM) NOT SHOWN.
11: NUTS (M14) NOT SHOWN.
17: LUG NUTS NOT SHOWN.
21: COTTER PINS (4 MM) NOT SHOWN.
24: BOLTS (10 X 90 MM) NOT SHOWN.
36: R-PIN (3 MM) NOT SHOWN.

Item 90153

7
16
18

20
22

For technical questions, please call 1-800-444-3353.

PAGE 22

Wiring Diagram

Note: Some trailer tail lights
will have two leads instead of three. They connect to the harness leads
the same way; brown to
brown, color to color.

BEARING PACKING INSTRUCTIONS

Important

Read and adhere to the following instructions; failure to read and obey all of the following instructions COMPLETELY will void the warranty and can result in damage to the trailer,
property damage, or SERIOUS PERSONAL INJURY.
Whenever a hub is disassembled (if a hub on a new unit requires assembly or a hub is disassembled for maintenance), the following procedure MUST be followed.
1.

Using a suitable solvent, thoroughly clean the
bearings and the rest of the parts in the Hub
assembly of all grease, dirt, metal shavings,
or any other foreign object. The parts must
be cleaned even if they are new or appear
clean.

With the grease-filled bearing packer in one
hand and the bearing in the other, press the
bearing into the grease, forcing the grease
inside the slots in the bearing, continue doing
this until every slot in the bearing is completely
full of grease.

Allow all pieces to dry completely.

Make sure that your hands are thoroughly
clean and the bearing packer (not included) is
also thoroughly clean.

Finish assembling the hub/wheel assembly
as explained in this manual, being careful
not to get any dirt or debris on any part of the
assembly.

Place fresh, clean bearing grease in
the packer.

Item 90153

For technical questions, please call 1-800-444-3353.

PAGE 23

Limited 90 Day Warranty
Harbor Freight Tools Co. makes every effort to assure that its products meet high quality and durability standards, and warrants to the original purchaser that this product is free from defects in materials and workmanship for the period of 90 days from the date of purchase. This warranty does
not apply to damage due directly or indirectly, to misuse, abuse, negligence or accidents, repairs
or alterations outside our facilities, criminal activity, improper installation, normal wear and tear, or
to lack of maintenance. We shall in no event be liable for death, injuries to persons or property, or
for incidental, contingent, special or consequential damages arising from the use of our product.
Some states do not allow the exclusion or limitation of incidental or consequential damages, so
the above limitation of exclusion may not apply to you. THIS WARRANTY IS EXPRESSLY IN LIEU
OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF
MERCHANTABILITY AND FITNESS.
To take advantage of this warranty, the product or part must be returned to us with transportation
charges prepaid. Proof of purchase date and an explanation of the complaint must accompany the
merchandise. If our inspection verifies the defect, we will either repair or replace the product at our
election or we may elect to refund the purchase price if we cannot readily and quickly provide you
with a replacement. We will return repaired products at our expense, but if we determine there is
no defect, or that the defect resulted from causes not within the scope of our warranty, then you
must bear the cost of returning the product.
This warranty gives you specific legal rights and you may also have other rights which vary from
state to state.

3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • (800) 444-3353

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History Software Agent          : Adobe InDesign 7.0, Adobe InDesign 7.0, Adobe InDesign 7.0, Adobe InDesign 7.0, Adobe InDesign 7.0, Adobe InDesign 7.0, Adobe InDesign 7.0, Adobe InDesign 7.0, Adobe InDesign 7.0, Adobe InDesign 7.0, Adobe InDesign 7.0, Adobe InDesign 7.0, Adobe InDesign 7.0, Adobe InDesign 7.0, Adobe InDesign 7.0, Adobe InDesign 7.0, Adobe InDesign 7.0, Adobe InDesign 7.0, Adobe InDesign 7.0, Adobe InDesign 7.0, Adobe InDesign 7.0, Adobe InDesign 7.0, Adobe InDesign 7.0, Adobe InDesign 7.0, Adobe InDesign 7.0, Adobe InDesign 7.0, Adobe InDesign 7.0, Adobe InDesign 7.0, Adobe InDesign 7.0, Adobe InDesign 7.0, Adobe InDesign 7.0, Adobe InDesign 7.0, Adobe InDesign 7.0, Adobe InDesign 7.0, Adobe InDesign 7.0, Adobe InDesign 7.0, Adobe InDesign 7.0, Adobe InDesign 7.0, Adobe InDesign 7.0, Adobe InDesign 7.0, Adobe InDesign 7.0, Adobe InDesign 7.0, Adobe InDesign 7.0, Adobe InDesign 7.0, Adobe InDesign 7.0, Adobe InDesign 7.0, Adobe InDesign 7.0, Adobe InDesign 7.0, Adobe InDesign 7.0, Adobe InDesign 7.0, Adobe InDesign 7.0
History Changed                 : /;/metadata, /metadata, /metadata, /;/metadata, /;/metadata, /;/metadata, /;/metadata, /;/metadata, /;/metadata, /;/metadata, /metadata, /;/metadata, /;/metadata, /;/metadata, /;/metadata, /;/metadata, /;/metadata, /;/metadata, /;/metadata, /;/metadata, /;/metadata, /;/metadata, /;/metadata, /;/metadata, /;/metadata, /;/metadata, /;/metadata, /;/metadata, /;/metadata, /;/metadata, /;/metadata, /;/metadata, /;/metadata, /;/metadata, /;/metadata, /;/metadata, /;/metadata, /;/metadata, /;/metadata, /;/metadata, /;/metadata, /;/metadata, /;/metadata, /;/metadata, /;/metadata, /;/metadata, /;/metadata, /;/metadata, /metadata, /;/metadata, /;/metadata
Create Date                     : 2012:10:12 15:51:42-07:00
Modify Date                     : 2012:10:12 15:51:48-07:00
Metadata Date                   : 2012:10:12 15:51:48-07:00
Creator Tool                    : Adobe InDesign CS5 (7.0.4)
Doc Change Count                : 812
Format                          : application/pdf
Producer                        : Adobe PDF Library 9.9
Trapped                         : False
Page Count                      : 24
Creator                         : Adobe InDesign CS5 (7.0.4)

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Harbor Freight 1090 Lb Capacity 40 1 2 In X 48 Utility Trailer Product Manual

Harbor-Freight-90153-Owner-S-Manual harbor-freight-90153-owner-s-manual

90154 90153

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