Assembly instructions for 1600UT knock down 1. Unpack parts from inside trailer bed, saving the cardboard lid to be used in Step 20. 2. With the help of 2 people, turn trailer bed upside down for assembly. Use cardboard from packaging to protect bed rails- be careful not to damage tailgate pins or D-rings. 3. Remove the 4 wooden blocks used for shipping and discard/recycle as shown in the photo left.
4. Mount subframe struts to bed with triangle section closest to tailgate, photo left. Each strut is either Right or Left. Place each strut on the inside portion, flush with the bed, use bolts from package labeled A. Leave bolts loose- do NOT tighten until Step 9. 5. Install bed rest to rectangular frame as shown in the photo above, use bolts from package labeled B. Notice the direction of the pivot point near the taillight points up in the same direction as the mounted bed rest.
. Install black box on bed rest, use bolts from package labeled C. 7. Take assembly portion from STEP 5 & 6 and install to struts as shown in photo above, use pivot bolts from package labeled D. 8. Install lift top mount cross bar as shown with direction of Brackets pointing to the front, use bolts from package labeled E. Leave bolts loose.
9. Tighten bolts that join bed and sub frame struts from Step 4. 10. Tighten bolts on lift top mount cross bar from Step 8. 11. Install lift, with motor closest to frame. Be sure to use the shorter spacers from package labeled F. 12. Install piston end of lift to cross bar using the wider spacers from package labeled G. 13. Connect the 2 wires from lift motor to black plastic box wires as shown in photo left.
14. Mount brake axle in front mounting holes with the swing arm pointing to the rear or taillight, use bolts from package labeled H. Connect the brake wires to either of the frame wires. Push excess wire into frame. 15. Mount idler axle in rear with the swing arm pointing to the rear or taillight, use bolts from package labeled H. Note: There are 3 packages of bolts labeled H which are used in steps 14, 15, & 18. 16. Mount each wheel/tire assembly to the hubs with the 4 tapered lug nuts.
17. On the tongue assembly, connect the male electrical connectors to the female electrical connectors, ensuring that the colors of the wires match. BE CAREFUL NOT TO DAMAGE WIRES. 18. Install the tongue assembly to the frame. Tighten to 50-71 ft-Ibs (68-96nm). Be sure the wires do not become pinched between the frame and the tongue. Use bolts from package labeled H. 19. Place tongue wires in hook on coupler. 20. Use cardboard and position as shown above to protect sides and wheels. 21.