NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION (NHTSA) If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, DO NOT USE THE VEHICLE. You should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying MasterCraft Boat 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.
Wa r n i n g s a n d C a u t i o n s Throughout this Manual the terms “WARNING” and “CAUTION” appear, alerting the trailer owner or operator to dangerous or potentially dangerous situations that may arise. Those terms have the following respective meanings whenever they appear herein. This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
towing, which may result in death, serious injury or property damage. (Page 3) If the total weight on the loaded trailer exceeds the load capacity of the hitch on the tow vehicle, then the trailer may break free, which may result in serious injury or death and/or property damage. (Page 5) The strength rating of EACH length of safety cable must be equal to the trailer’s GVWR (Gross Vehicle Weight Rating). (Page 5) Trailer sway control devices that restrict the operation of the actuator MUST NOT be used.
ing could result in serious injury or death and/or property damage. (Page 15) The breakaway system actuators will apply the trailer brakes if the trailer becomes completely detached from the tow vehicle while under power. Failure to properly connect the breakaway system prior to towing may result in serious injury or death and/or property damage. (Page 15) The brake lockout bracket must be removed before towing or the trailer brakes will not work.
Use great care when walking, standing or loading and unloading boats on or around any launch ramps as some launch ramps may be slippery when wet. (Page 21) Wet brakes may not hold and/or may cause brakes to have diminished performance characteristics. A few braking applications at a slow speed will help to dry them out. Extra care must be used when braking after brakes have become wet.
Table of Contents NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION (NHTSA) Statement............................................................................................... i MasterCraft Trailer...................................................................................................... i Warnings and Cautions............................................................................................. ii Quick Tips................................................................................
u u u u u u u u u u u Q uick Tips Here are some quick tips for maintaining the trailer in excellent condition. chips in the paint, especially on the axles and frame, result when these surfaces are subjected to repeated or severe hits by external objects. Usually, these are gravel or asphalt chips thrown up by the rear tires of the tow vehicle. Over time, rust may develop where paint has been chipped away, and this is not covered by the Limited Warranty for the trailer.
u u u parking brake, shift into Park, and then remove your foot from the brake pedal. Following this parking sequence is important to be sure your vehicle does not become locked in Park because of extra load on the transmission. For manual transmissions, apply the parking brake and then turn the vehicle off in either first or reverse gear. When uncoupling the trailer, place blocks at the front and rear of the trailer tires to ensure that the trailer does not roll away when the coupling is released.
L o a d - C a r ry iCheck n gthe certification C a p alabelcattached i t yto the front left side of the trailer. It will show the maximum load-carrying capacity of the trailer. It will also show the Gross Vehicle Weight Rating (GVWR). The Gross Vehicle Weight Rating (“GVWR”) is the estimated total weight of a road vehicle that is loaded to capacity, including the weight of the vehicle itself. Therefore, the maximum load-carrying capacity of the trailer is the GVWR, less the weight of the empty trailer.
It is extremely important that a minimum of five percent (5%) and a maximum of ten percent (10%) of the total weight on the trailer be felt at the trailer coupling ball when the tongue is parallel to the ground. A bathroom scale can be used for this determination. For example, if the gross weight of the trailer, boat and gear is 3,000 pounds, the weight on the tongue should not be more than 300 pounds, but not less than 150.
This can be corrected in a number of different ways. For example, air-pressure adjustable shock absorbers may be installed on the tow vehicle, or switch from a weight-carrying hitch to a weight-distributing hitch. Again, consult with the tow-vehicle’s dealer or manufacturer. In general, for Class 3 rigs (3,500 to 5,000 lbs.), a two-inch (2”) ball is the requirement. For Class 4 (5,000 to 10,000 lbs.), a ball of either 2” or 2-5/16” will be required.
The strength rating of EACH length of safety cable must be equal to the trailer’s GVWR (Gross Vehicle Weight Rating). Trailer sway control devices that restrict the operation of the actuator MUST NOT be used. These devices can limit how well the trailer brakes work. Before each trip, ensure that the proper cables are correctly attached between the tow vehicle and the trailer.
If the breakaway cable is accidentally pulled and the brakes applied, determine why it happened and fix the problem. Inadvertent setting of the brakes by pulling the breakaway cable is a common mistake. To prevent light pulls from accidentally setting trailer brakes a small metal clip has been installed on breakaway cables in front of the indicator bead. The clip will not inhibit the action of the breakaway mechanism during actual breakaway conditions.
with your authorized MasterCraft dealer whether your model has the clip.) Hold the clip with a set of pliers and insert over the cable. Use a second set of pliers to gently close the opened end of the clip. The clip should be free to move on the cable. The breakaway system reset tab must be pushed up after the clip installation and anytime the cable has been pulled. t r a i l e r w i n c h a s s e m b ly Maintain a firm grip on the winch handle at all times.
Wa r n i n g s atReadT and o nadhere gu e to all warning labels, especially those that appear on the pivot tongue. Ensure the swing tongue is folded fully forward, the pivot pin is installed, and the keeper pin is installed in the bottom of the pivot pin before towing. When folding the swing tongue open or forward to the fully closed position, be sure that the brake hose is not kinked or pinched in any way. A pinched or kinked brake hose will cause the brakes to drag and overheat.
To open the coupler: Remove the hitch pin from the hole in the side of the coupler. Push the button on top of the hand to the side. While holding the button to the side, raise the handle by lifting the front with two fingers. The coupler should unlatch easily. If not, the ball may be over-sized or egg-shaped, or foreign matter could be lodged in the coupler ball socket, or the coupler is pushing on the hitch ball. Check to make sure the wheel on the tongue jack is raised or that you are not parked downhill.
Lights Before each use make certain that all trailer lights are in proper working order, to reduce the risk of serious injury, death and/or property damage. The MasterCraft trailer harness was specifically designed to mate with O.E.M. automotive equipment. This harness is designed to disengage the trailer brakes with the use of the tow vehicle’s O.E.M. harness. Note: See an authorized MasterCraft dealer if the tow vehicle does not have the correct trailer harness.
mild detergent and/or mild degreaser. A quality spray-on wheel cleaner may also be used. Ensure that any product used is specifically indicated for use on aluminum. (Many cleaners are too harsh and will result in pitting or other damage to the wheel surface.) Many car washes use strong chemicals and should be avoided when that is the case.
• gear, and retain but do not re-use involved lug nuts, wheels and studs. Do not repair or service the trailer yourself. Instead, call a trained technician. Use the following pattern to tighten lug nuts. On first torqueing pass tighten to 45 ft.-lbs. On second pass tighten to 70 ft.-lbs. On third pass tighten to 90 ft.-lbs. On fourth pass tighten to a reading between 110 ft. lbs-120 ft.-lbs. Tires The most common cause of trailer tire trouble is under-inflation.
it is strongly recommended that the owner not mix radial and bias tires as it may affect the trailer/tow vehicle handling and safety. MasterCraft dealers offer replacement tires; if the owner chooses to go elsewhere, be certain that the replacement tires meet the manufacturer’s requirements and integrate with any tires remaining on the trailer.
The trailer’s brakes are designed to energize automatically when the tow vehicle’s brakes are applied. These are known as “surge brakes.” (Note: Some jurisdictions do not allow surge brakes. Always check within the locality in which you will be towing.) When the vehicle slows down or stops, the forward momentum (surge) of the trailer against the hitch ball develops hydraulic pressure in a master cylinder inside the trailer brake actuator.
brakes not flushed out, severe corrosion can occur. Try the brakes before each trip. On a regular basis, have the brake linings inspected, necessary adjustments made and any damaged or worn parts replaced by an authorized MasterCraft dealer. Wet brakes usually do not hold especially well. If the wheels have been in water, several brake applications at slow speeds should dry them out.
When pulling the trailer forward and the actuator extends, the brake lockout should fall out of the slot. This ensures that the actuator will function when stopping. The brake lockout bracket must be removed before towing or the trailer brakes will not work. Manual bleeding of brakes The following procedure should be performed only by skilled mechanics. MasterCraft recommends that it be completed by an authorized MasterCraft dealer. Check that all hydraulic fittings are secure.
6. 7. 8. 9. 10. tighten the bleeder screw before releasing the push rod. During this procedure, the master cylinder reservoir fluid level must be maintained at no less than half full. Repeat Steps 4 and 5 for the other brake, as well as the brakes on the front axle of tandem axles. If installation is on a tandem-axle trailer, repeat the bleeding procedure on the rear axle brakes for a second time to assure purging of all air in the system.
Also, it is very important to be sure that the transom of the MasterCraft boat is resting fully and securely on the supports provided at the rear end of the trailer, and that it remains in place when parked or underway. Tie-downs have been added on both the bow and transom of the boat and must be used while trailering. H itching Up • Hitch only to the ball size marked on the coupler. • • • Be certain that the ball clamp captures the ball and lever or that the hand wheel is fully closed or tightened.
T rWithaai boat l etrailer r inT tow, ips & Techniques an operator will be driving down the road with a vehicle combination that is longer, heavier and sometimes wider and taller than the tow vehicle. This means the operator should make a few adjustments to normal driving practices to compensate for the differences. Here are a few tips: • Take a shakedown cruise.
• • • • Signal your intentions. Well before stopping, turning, changing lanes or passing, use turn signals to let other vehicles know what you intend to do. Drive in the gear recommended by the tow-vehicle manufacturer. If the tow vehicle has a manual transmission, traveling in lower gears when going up steep hills or over sand, gravel or dirt roads will ease the load on the engine and transmission. When driving on long downhill grades, try to avoid downshifting.
• Prepare for launching. Install the drain plugs and detach the trailer tie-downs. • Slowly back the trailer down the ramp. If possible, have someone stand to one side of the ramp to provide directions. Backing up a trailer can be tricky. A good way to simplify the procedure is to grasp the steering wheel with one hand at its lowest point (6 o’clock). To make the trailer go right, move your hand on the wheel to the right; to make the trailer go left, move your hand to the left.
T rTheatrailer i ljacke randilugnwrench g that T icame p swith the tow vehicle may also work on the trailer, but don’t count on it! Check to make sure. • The trailer will look better and last longer if it is rinsed off with fresh water several times a year. If the boat is run in brackish or salt water, the trailer should be rinsed thoroughly after every trip because of residual effects of the brackish or salt water.
L i m i t e d Wa r r a n t y S t at e m e n t 1. Limited Warranty and Term. MasterCraft Boat Company, LLC (“MasterCraft”) warrants to the original retail purchaser that the trailer shall be free from material defects in materials and workmanship to the extent set forth below, under normal use and when operated and maintained in accordance with MasterCraft’s instructions, for the period indicated: 1.1 Trailer and Trailer Component Parts.
(h) (i) (j) (k) (l) damage to any component parts and accessories not manufactured by MasterCraft; damage to the trailer and its parts or components due to abrasions, rock chips, rust, improper care or maintenance, or use in salt or brackish water; however, the finishes of galvanized trailers, which are designed for use in salt or brackish water, are warranted to be free from damage resulting from use in salt or brackish water for one (1) year from the date of the original retail purchase or the initia
OR OTHERWISE, EVEN IF MASTERCRAFT HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES OR SUCH DAMAGES COULD REASONABLY HAVE BEEN FORESEEN BY MASTERCRAFT. However, some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you. 4.2 Purchase Price Limitation.
6. Warranty Claims. In order to maintain warranty service under this Limited Warranty, the owner must return the defective trailer or component part to an authorized MasterCraft repair facility, or to MasterCraft’s factory at the below address, within the applicable warranty period.
M (Note a i that n tfailure e nto follow a nthesec routine e procedures may result in failures that are not covered under warranty.) Failure to follow maintenance procedures as outlined in this Owner’s Manual may result in component failure. Failure may also result in loss of control or other malfunction that could potentially lead to serious injury or death! Such failure is not covered under warranty.
time. Any exposure to a hard winter climate, particularly road salt and/or chemicals, requires immediate cleaning just as submersion in salt water. NEVER CLEAN HOT WHEELS. All wheels to cool or cool them with running water. If the wheels are too hot, significant damage can occur to the wheels. It is also important to seal the wheels with a sealant that reduces static and resists brake dust. Check at an automotive supply store for an appropriate sealant.
• • • • • • • • • • • • Inspect the tow hitch for corrosion or damage. Repair or replace components as necessary. Check for wear on the hitch ball. The ball diameter must be in the range of 1.970”2.00” when measured in all directions. If the ball is worn, it is UNSAFE and must be replaced. Check the coupler mechanism for smooth operation. If the button is hard to push or the latch handle does not spring open after being disengaged, lubricate the points on the coupler latch mechanism.
• • • Relieve the load on the tires by supporting the trailer frame with concrete blocks or jack stands. Lubricate moving parts such as the rollers and winch, as well as the ball coupler. Tighten any loose nuts and bolts. Extended storage (in excess of one year): Follow the recommendations listed above for storage of several months duration. Additionally: • Check the brake system for fluid level in the master cylinder. If the fluid level is low, air may be trapped in the brake lines.
If the latch handle does not close freely, DO NOT tow the trailer until the cause of the problem is located and corrected. Forcing the latch handle closed will make opening the latch handle extremely difficult. Problem: Squeaking, clunking and clattering at the actuator. Possible cause: Remedy: The hitch ball requires lubrication. Lubricate with conventional multi-purpose lubricant or commercial lubricant made for hitch balls.
Possible cause: Remedy: Contaminated brake linings. Fix the cause of the contamination, which will be a leaky wheel cylinder or hub grease seal. Replace the linings and clean the braking surface on the rotor. Possible cause: Remedy: Possible cause: Remedy: Corroded master cylinder bore or Replace the actuator master cylinder. rust from the brake line. Breakaway cable has been pulled. Reset the push rod release bracket.
Possible cause: Remedy: Possible cause: Remedy: Leaky or seized brake wheel cylinder. Damaged or frozen brake mechanism. Replace/rebuild the wheel cylinder and replace the brake shoes if contaminated with brake fluid. Clean the drums and other hardware, readjust the brakes and bleed the brake system. Rebuild or replace the brake unit. Problem: More than one brake is overheating. Isolate the problem to the actuator or the brakes by: 1. 2. 3. 4.
