Burley CargoD User manual

Burley CargoD User manual
Owner’s Instruction and
Safety Manual
cargo
Nomad and Flatbed™
Stroll
Bike
Ski
Jog
Contents
Owner’s Instruction
and Safety Manual
Burley Nomad
and Flatbed™
3
Introduction
3
Safety Guidelines
3
Tool List
4
Mounting the Light
4
Attaching Wheels
4
Installing Side Rails
5
Mounting Reflectors
6
Installing Tailgate and Splashguard
6
Installing Roll Bar and Cover
6
Installing Tow Bar
7
Installing Safety Flag (Nomad Only)
7 Hitching Trailer to Your Bicycle
8 Safety Checklist
8
Maintenance and Storage
9 Nomad Replacement Parts and Diagram
10 Flatbed Replacement Parts and Diagram
12 Warranty
Congratulations!
Your Burley® trailer is the leading choice of refined bicycle
trailer owners worldwide. Every effort has been made to
ensure your purchase is of top quality and proven design,
ready to provide you with many years and miles of happy,
safe trailering.
Please go to www.burley.com or contact us at
burley @ burley.com to register your warranty information.
IMPORTANT
IT IS VERY IMPORTANT FOR YOU TO FAMILIARIZE YOURSELF
WITH YOUR BURLEY BY READING THIS ENTIRE MANUAL
BEFORE USE. IF YOU HAVE ANY QUESTIONS, PLEASE CONTACT
YOUR AUTHORIZED BURLEY DEALER.
Introduction
Once you’ve done the initial assembly and read the safety
guidelines, you’re ready to go! Before trailering, be sure you
have the tow bar, trailer wheels and hitch securely attached.
Note:Any reference to left or right is made in direction
of travel, as if you were standing behind the trailer,
looking forward.
Safety Guidelines
WARNING
BICYCLING WITH A TRAILER, AND BICYCLING IN GENERAL, CAN
BE HAZARDOUS. FAILURE TO OBSERVE ANY OF THE SAFETY
GUIDELINES IN THIS MANUAL COULD RESULT IN AN ACCIDENT
AND SERIOUS INJURY OR DEATH.
7. Only use factory-supplied wheels, with the tires inflated
to the pressure recommended on the tire side wall.
Check pressure before each use.
8. Clamp the hitch securely to the bicycle frame, and check
for a tight attachment before each use.
9. Use the safety flag. (Nomad Only)
10.Do not make alterations to the trailer. Contact your
Authorized Burley Dealer or go to www.burley.com for
replacement of any damaged, worn-out or missing parts.
11.Do not use your trailer on icy roads or when inclement
weather makes cycling hazardous.
12.The use of a mirror on your bicycle is recommended.
13.For emergencies, breakdowns or flat tires, pull
completely off the road and move to a safe area before
doing repairs.
Parts Bag Contents:
Nomad: (1) Red light with bracket (2) Roll bar knobs
(1) Hitch (1) Burley Owner’s Instruction and Safety Manual
Flatbed: (4) Retaining pins (2) Pair tie-down straps
(2) Clear reflectors with brackets/screws
(2) Red reflectors with brackets/screws
(1) Hitch (1) Burley Owner’s Instruction and Safety Manual
Tools Required: Phillips Screwdriver
1. Inspect and maintain your bicycle and trailer regularly.
See “Safety Checklists”.
2. Because of the trailer’s additional weight, a bicycle
pulling a trailer is heavier and less responsive. Avoid
sudden swerving, rocks and curbs. Experiment with the
loaded trailer in an uncongested area until you become
familiar with it.
3. The total weight limit for the trailer and cargo is 100 lbs
(40 kg in Europe). Load cargo securely in the center,
forward of the axle and as low as possible.
4.
Observe recommended speed limits: a maximum of
15 mph (24 km/h) on smooth, straight roads and
5 mph (8 km/h) or less when turning or on
uneven roads.
5. Never pull your trailer with a motorized vehicle.
6. The cyclist must wear a helmet.
B U R LEY N O MAD AN D FLATB E D OWN E R’S I N STR U CTI O N AN D SAFET Y MAN UAL
WARNING
TRAILERS CAN TIP OVER, CAUSING DAMAGE TO TRAILER AND
SERIOUS INJURY TO CYCLIST. AVOID CAUSES OF TIP OVER,
ESPECIALLY:
• HITTING POTHOLES, CURBS, OTHER ROAD OBSTRUCTIONS
• TAKING TURNS TOO FAST
• SUDDEN SWERVING
• IMPROPER WHEEL INSTALLATION OR TIRE INFLATION
Wheel
Bracket
Red Light
Main
Frame
Tube
Mounting the Light
Nomad:
1. Insert batteries into light.
photo 1: Nomad light/bracket mounted on rear corner of main frame tube
2. Screw light and bracket together.
3. Mount light/bracket horizontally on rear corner of
main frame tube, on side closest to traffic. Photo 1
Attaching Wheels
1. Insert wheel axle assembly completely into trailer
axle. Figure 1
2. Close quick release lever, with lever aimed at trailer rear.
A properly adjusted quick release lever should leave an
imprint on your palm when the lever is rotated to the
closed position. Figure 2
3. Verify that tires are inflated to pressure marked on tire
side wall.
Trailer
Rear
figure 1: Quick release lever in unlocked
“open” position (Top View)
Side Rail
4. To remove wheel from trailer axle, open quick
release lever.
Side Rail Guide
WARNING
MAKE SURE WHEELS ARE HELD SECURELY, WITH WHEEL
SHAFT FULLY INSERTED INTO HOLLOW AXLE. YOU SHOULD NOT
BE ABLE TO ROCK OR SHIFT WHEELS. IMPROPERLY INSTALLED
WHEELS CAN FALL OFF, CAUSING AN ACCIDENT OR
SERIOUS INJURY.
C-Shaped Hold-down
Installing Side Rails
photo 2
Nomad:
1. On trailer sides, flip the four C-shaped side panel
hold-downs to outside of trailer frame. Photo 2
2. Slide vertical side rails down over side rail guides on
trailer sides, with narrower end of side panels to the rear
and “Burley” logo facing outward. Photos 2 & 4 3. Snap all four side panel hold-downs over side panel
tubing. Photo 3
photo 3: Hold-down locked over side panel tubing
B U R LEY N O MAD AN D FLATB E D OWN E R’S I N STR U CTI O N AN D SAFET Y MAN UAL
figure 2: Quick release lever in locked
“closed” position (Top View)
WARNING
Trailer Rear
Narrow End
of Side Panel
IF ALL HOLD-DOWNS ARE NOT SNAPPED IN PLACE BEFORE
USING THE TRAILER, THE SIDE RAILS CAN SHIFT OR COLLAPSE,
RESULTING IN THE LOSS OF CARGO.
Flatbed:
1. Slide ends of side panel rail into front and rear receivers
on side of frame, matching holes in plastic tubing ends
with holes in receivers. Photo 5
2. Insert retaining pins through holes on all four corners,
and lock retaining hoops securely. Photo 5
photo 4: Nomad side panel orientation
Side Panel Rail
Mounting Reflectors
Flatbed:
1. Screw reflectors and brackets together.
2. Mount clear reflectors/brackets horizontally on front
corners of side panel rail tubes. Photo 6
Retaining Pin
Front
Receiver
Front Tow
Bar Mount
3. Mount red reflectors/brackets horizontally on rear
corners of side panel rail tubes. Photo 7
Tr ailer Fr on t
photo 5: Flatbed side panel attachment
Clear
Reflector
Reflector
Bracket
Side Panel
Rail Tube
ile
Tra
rF
r on
t
photo 6: Flatbed clear reflector/bracket mounted on front corner of
side panel rail tube
Trailer
Rear
Red
Reflector
Side Panel
Rail Tube
Bracket
photo 7: flatbed red reflector/bracket mounted on rear corner of
Side panel rail tube
B U R LEY N O MAD AN D FLATB E D OWN E R’S I N STR U CTI O N AN D SAFET Y MAN UAL
Installing Tailgate and Splashguard
Buckle
Nomad:
Webbing Strap
1. Loop tie-down straps over corners of side panels and
join male buckle sections on straps to female buckle
sections inside trailer. Figure 3 & Photo 8
2. To accommodate different sizes of cargo, tighten or
loosen the webbing straps as needed. Photo 8
Installing Roll Bar and Cover
Nomad:
1. Place cover over side panels, with “Nomad” logo at trailer
front. Figure 3
Trailer
Rear
photo 8
2. Slip one roll bar knob through a grommet on
cover. Figure 3
Cover Grommet
3. Slide roll bar through casing in divider, and match roll bar
end with its corresponding hole on side rail.
Side Rail
Roll Bar
Roll Bar Knob
4. Thread roll bar knob through side rail, and tighten.
5. Repeat for knob on other side.
6. Loop O-rings on cover over trailer frame tube ends.
Make sure cover extends over top of side panels.
O-Ring
Installing Tow Bar
1. Slide tow bar through both tow bar mounts on left side.
2. Match rear tow bar hole with rear mount hole.
Tailgate
Webbing Strap
3. Insert the retaining pin through both holes, and lock
retaining hoop securely. Photo 9 & Photo 10
Splashguard
Trailer Frame
figure 3: Nomad
Retaining Pin
Tow Bar Mounts
photo 9: Nomad tow bar installation
B U R LEY N O MAD AN D FLATB E D OWN E R’S I N STR U CTI O N AN D SAFET Y MAN UAL
Trailer Front
WARNING
NEVER OPERATE TRAILER WITHOUT RETAINING PIN LOCKED
IN PLACE. AN UNLOCKED TOW BAR CAN LOOSEN OR DETACH,
CAUSING ACCIDENT RESULTING IN SERIOUS INJURY.
Installing Safety Flag
Nomad:
Join flag pole sections together and insert end into flag pocket on
inside of left side panel.
Retaining Pin
Tow Bar Mounts
Trailer Front
photo 10: Flatbed tow bar installation
WARNING
DO NOT USE TRAILER WITHOUT SAFETY FLAG.
Hitch
Hitching Trailer to Your Bicycle
Quick
Release
1. Remove rear quick release lever assembly from bike.
Nut
2. Match hole on flat side of hitch upper arm to left (nonchain ring side) rear dropout hole.
3. Loosely reassemble quick release assembly through
hitch, dropout and wheel. Figure 4
4. Slide flex connector between hitch side arms, and match
holes. Racks, bags, or fittings should not interfere with
hitch.
5. Open retaining pin and insert through hitch and flex
connector holes. Rotate and close retaining hoop.
6. Tighten and close quick release lever, with lever pointing
to rear of bike. A properly adjusted quick release lever
should leave an imprint on your palm when the lever is
rotated to the closed position.
figure 4
Safety strap
wrapped twice
around chainstay
Hitch
Quick
Release
Lever
7. Wrap safety strap twice around inside of chain stay.
Fasten hook to D-ring on underside of tow bar
end. FIGURE 5
8. To remove trailer from bicycle, unfasten clip from D-ring
and remove retaining pin.
WARNING
QUICK RELEASE LEVER MUST BE IN CLOSED POSITION AND
HITCH SAFETY STRAP PROPERLY INSTALLED. HITCH MUST NOT
INTERFERE WITH RACKS, BAGS OR FITTINGS. INSPECT HITCH
AND TOW BAR FREQUENTLY FOR DAMAGE OR LOOSE FASTENERS. DAMAGED, IMPROPERLY INSTALLED OR INTERFERING
PARTS CAN CAUSE ACCIDENTS RESULTING IN SERIOUS INJURY.
Flex
Connector
Retaining Pin
Hook fastened to
D-ring under tow bar
figure 5
B U R LEY N O MAD AN D FLATB E D OWN E R’S I N STR U CTI O N AN D SAFET Y MAN UAL
Safety Checklists
Check Before Each Ride:
✓
✓
✓
✓
✓
✓
✓
✓
✓
Wheels tightly attached, with quick release levers securely locked
Tires inflated to recommended pressure on tire side wall
Hitch properly secured with safety strap in place
Locked retaining pin for tow bar
Maximum load 100 lbs (40 kg in Europe)
Bicycle safety check, especially brakes and tires
Helmet for cyclist
Safety flag in place (Nomad Only)
Cargo loaded and secured correctly
Monthly Checklist
✓
✓
✓
✓
✓
✓
Inspect tow bar, hitch, frame tubing, flex connector and hardware for damage
Inspect tires for wear and cracks
Inspect wheels for trueness and cracks
Inspect wheel bearings for wear
Inspect fabric parts for rips, abrasion, or missing or damaged hardware
Contact your Authorized Burley Dealer for replacement of any damaged or worn-out parts
Maintenance and Storage
Hitch and Tow Bar Maintenance
Store trailer indoors if possible. Do not use or store trailer at temperatures below 32˚F (0°C), as the hitch flex connector can
become brittle and possibly break, causing an accident resulting in serious injury.
Fabric Care
Hand wash fabric parts with mild soap or detergent and warm water. For heavy soiling, use a nylon bristle brush. Do not use
bleach. Polyester fabric will eventually fade, especially when exposed to direct sunlight. Wipe dry (to help avoid mildew) and
store out of direct sunlight in a dry, well ventilated area, or use a Burley Trailer Storage Cover to protect your trailer. Replace
any damaged parts.
B U R LEY N O MAD AN D FLATB E D OWN E R’S I N STR U CTI O N AN D SAFET Y MAN UAL
2009 Nomad Replacement Parts and Diagram
Diagram #
Part #
1
960041
Forged Standard Hitch
Description
Warranty
lifetime
2
960009
Safety Flag
1 year
3
4325401
Tonneau Cover
1 year
4
4326502
Bag
1 year
5
950022
Left Side Panel on Frame
1 year
6
950023
Right Side Panel on Frame
1 year
7
250122
Tow Bar Assembly
lifetime
8
160021
Wheel (SOLD INDIVIDUALLY)
5 years
9
950019
Tow Arm Guide Kit
5 years
10
950026
Side Rail Posts (set of 2)
lifetime
11
950027
Snap Coupling Kit (Set of 4)
5 years
12
4310007M
Rollbar with Knobs
lifetime
13
950072
Nomad Frame Kit
lifetime
14
950029
Axle Tube Assembly
lifetime
15
950038
Flex Connector for Square Tow Bar w/ Safety Strap
5 years
Please go to www.burleygear.com for updated product parts list and diagrams
B U R LEY N O MAD AN D FLATB E D OWN E R’S I N STR U CTI O N AN D SAFET Y MAN UAL
2009 Flatbed Replacement Parts and Diagram
Diagram #
Part #
1
960041
Forged Standard Hitch
Description
950096
Fabric Floor (NOT SHOWN)
1 year
2
250122
Tow Bar Assembly for Square Tow Bar
lifetime
3
160021
Wheel (SOLD INDIVIDUALLY)
5 years
950005
Tow Bar Receiver Kit (NOT SHOWN)
5 years
4
950073
Side Rails (set of 2)
lifetime
5
4130010
Hold Down Straps (set of 2)
1 year
6
950074
Flatbed Frame Kit
lifetime
7
950097
Axle Assembly
lifetime
8
950038
Flex Connector for Square Tow Bar w/ Safety Strap
5 years
Please go to www.burleygear.com for updated product parts list and diagrams
10
B U R LEY N O MAD AN D FLATB E D OWN E R’S I N STR U CTI O N AN D SAFET Y MAN UAL
Warranty
lifetime
Notes:
B U R LEY N O MAD AN D FLATB E D OWN E R’S I N STR U CTI O N AN D SAFET Y MAN UAL
11
Burley Trailer Limited Warranty
Burley trailers are warranted from date of purchase against defects in materials and workmanship under normal use and service. Burley
will repair or replace parts it determines to be defective as follows: fabric parts for one year, plastic parts for five years and durable frame
parts for the lifetime of the trailer. The Burley trailer owner must present the trailer for repair at place of purchase, with an original sales
receipt or similar proof of purchase. This warranty applies only to the original owner and is nontransferable. Burley can not be responsible
for failure due to improper assembly, modification of parts or instructions, neglect, abuse, accident, and/or normal wear. The warranty does
not cover any trailer used for rental, competition, or commercial use.
Burley neither assumes nor authorizes any person to assume any other liability in connection with this Burley product, and there are no
oral agreements or warranties collateral to or affecting this agreement. This warranty gives you specific rights. You may also have other
rights which vary by state or country.
BU R LEY DES IG N
4020 Stewart Rd. Eugene, OR 97402
PH 541.687.1644 800.423.8445 FAX 541.687.0436
burley @ burley.com : burley.com
Copyright ©2008 by Burley Design LLC. “Burley” is a registered trademark of Burley Design LLC
170099 Manual Cargo Trailer Nomad Flatbed r2 : RTFM Rev 06.08
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