Burley Flatbed Product manual

Burley Flatbed Product manual
NOMAD™
FLATBED™
Owner’s Instruction and Safety Manual
Congratulations!
Introduction
Your Burley trailer is the leading choice of discriminating 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.
Your Burley is shipped almost completely assembled from the factory. Your
final assembly should take about 5 to 10 minutes. Once you’ve read the safety
guidelines, you’re ready to go! Before trailering, be sure you have a thorough
understanding of the trailer hitch operation. Review the loading guidelines,
and make sure the trailer wheels and hitch are securely attached.
®
IMPORTANT:
Because some of the features and guidelines for using
your Burley merit close attention, it is very important that you familiarize yourself with the trailer by reading this entire manual before use. If
you have any questions, please contact your Authorized Burley Dealer or
check our website at www.burley.com.
NOTE:
Any reference to left or right is made in the direction of travel,
as if you were sitting on the bike seat looking forward.
Safety Guidelines
Table of Contents
Bicycling with a trailer is different from bicycling without one, in ways which
aren’t always obvious. It is essential that you read and understand all of the
following safety guide lines—in addition to the warnings and instructions in
the following sections—prior to using your trailer. Contact your Authorized
Burley Dealer or Burley if any of these instructions are unclear.
Introduction
Pg.
3
Safety Guidelines
Pg.
3
Hardware Bag Contents and Tool Lists
Pg.
5
Mounting the Reflectors
Pg.
6
Attaching the Wheels
Pg.
6
Installing the Side Rails (Nomad Only)
Pg.
7
Use a Well-Maintained Bicycle and Trailer
Installing the Tailgate and Splashguard (Nomad Only)
Pg.
8
Installing the Rollbar and Cover (Nomad Only)
Pg.
8
Installing the Tongue
Pg.
9
Use a bicycle which is in good working condition, with good brakes. A frequent safety check of your bicycle is essential. Inspect and maintain your
trailer as outlined in the “Safety Checklists” of this manual. Have your
Authorized Burley Dealer maintain and inspect your bicycle and trailer if you
are not qualified to do so.
Installing the Safety Flag (Nomad Only)
Pg.
10
Hitching Your Burley to Your Bicycle
Pg.
10
Loading Your Trailer
Pg.
11
Safety Checklists
Pg.
12
Maintenance and Storage
Pg.
13
Parts Lists and Diagrams
Pg. 14-17
Warranty
Pg.
18
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 accident and serious injury or death.
Starting and Stopping
Because of the trailer’s additional weight, a bicycle pulling a trailer will be
slower to start and stop, and because of its length, requires more time to
cross streets or paths. Your entire vehicle is heavier and less responsive.
Think ahead and anticipate stops, turns and starts. Note that your trailer extends further out on the left; allow for this difference when turning, passing
pedestrians or approaching obstacles, such as posts on bike paths. Experiment with a loaded trailer in an uncongested area to become familiar with
how your heavier, longer vehicle responds.
BURLEY TRAILER OWNER’S INSTRUCTION AND SAFETY MANUAL
Prevent Trailer Tip Over
Know Your Trailer Hitch
Like automobile and motorcycle trailers, bicycle trailers can tip over. Do not
pull your trailer over curbs or hit holes or other road obstructions. Make sure
your load is centered and securely fastened down. Do not make high-speed
turns or descents when pulling the trailer. Always corner with caution at
5 mph or less, as the trailer cannot lean into a turn the way a bicycle can.
Do not travel faster than 15 mph—all road irregularities and your slower reaction time are greatly magnified.
Clamp the hitch securely to the bicycle frame, and check for a tight attachment each time you use the trailer. Refer to the “Hitching Your Burley to Your
Bicycle” section for the proper installation and use of your hitch.
WARNING
Trailers can tip over, causing damage to the trailer and serious
injury to the cyclist. AVOID causes of tip over, especially:
• Inadequately secured or
centered load
• Hitting potholes, curbs and
other road obstructions
• Taking turns too fast
•
•
•
•
Sudden swerving
Off-banked turns
Improper wheel installation
Improper tire inflation
No Motorized Vehicles
Never pull your Burley trailer with a motorized vehicle, as the increased acceleration and speed could damage the trailer or cause it to tip over.
Carry Cargo Only
The Nomad and Flatbed are designed to carry only cargo. Never use them for
transporting people!
Wear a Helmet
Numerous studies have shown that head injury is the leading cause of bicycling fatalities. Helmets prevent or reduce bicyclists’ head injuries; it is
essential that you use an approved bicycling helmet at all times.
Proper Wheels and Tires are Essential
Use Your Safety Flag (Nomad™ Only)
Always use the safety flag—it will help make you more visible to motorists
and other cyclists.
IMPORTANT:
Please verify that you have received all of the contents
listed. Do not proceed with the assembly if any parts are missing; contact
your Authorized Burley Dealer or Burley immediately for replacement parts.
Hardware Bag Contents: Nomad™:
(2)
(2)
(2)
(2)
(2)
(1)
(1)
Reflector Brackets
Self-tapping Reflector Bracket Screws
Roll-bar Knobs
Red Reflectors
Reflector Screws
Warranty Card
Burley Owner’s Instruction and Safety Manual
Flatbed™:
(2)
(2)
(2)
(2)
(1)
(1)
Quick-release Levers
Pair Tie-down Straps
Red Reflectors
Reflector Screws
Warranty Card
Burley Owner’s Instruction and Safety Manual
Tools Required: Phillips Screwdriver, Flat Blade Screwdriver
Nomad only: 5/16”, 8 mm or Small Adjustable Wrench
Note: The European models have an additional light hardware bag.
Use only the factory-supplied wheels, and keep them properly maintained.
Inflate the tires to 30–35 P.S.I. and check the pressure before each use. Do
not use higher-pressure tires or knobbies. We recommend using only tires
with street tread.
BURLEY TRAILER OWNER’S INSTRUCTION AND SAFETY MANUAL
BURLEY TRAILER OWNER’S INSTRUCTION AND SAFETY MANUAL
Mounting the Reflectors
Nomad : The reflector brackets mount on the outside rear of each side
panel, 2.5” up from the plastic connector on the side panel. (The holes
for the mounting screws are covered by the fabric.)
To mount the bracket, insert a self-tapping bracket
screw through the hole in the curved section of the
reflector and drive the screw through the fabric,
2.5”
into the hole in the rear side panel frame. (This
does not harm the fabric.) Then mount the reflector
onto the bracket with the reflector screw. Repeat for Right
the bracket and reflector on the other side panel. rear
See illustrations.
™
Flatbed™: The reflectors are mounted to the reflector
brackets on the rear of the main frame tube. Snap
the posts on the reflectors into the openings in the
brackets, and with the provided screws, screw the
pieces together. Tighten the screws snugly, making
sure the reflector faces away from the trailer.
Flatbed™: Remove the thumb nut from the quick-release
lever. Insert the quick-release lever through the hollow
axle of the wheel, making sure the lever is on the flat
side of the wheel and the springs are mounted on each
side as shown in the illustration. With the quick-release
lever in the unlocked position, place the wheel into the
dropouts, making certain that the axle goes all the way
into the slots. Once the wheel is fully seated, replace
and tighten the thumb nut. You should feel resistance
halfway through closing the lever. Position the quickrelease lever so that it is aimed to the rear of the trailer in the “CLOSED” position (the lever is marked for
OPEN or CLOSED positions). Repeat for the other wheel.
Note: Wheels are not centered on the axle.
IMPORTANT:
Wheels are dished off-center and must be installed so
that tires are offset away from side rails, closest to outer frame.
WARNING
Attaching the Wheels
First, verify that the tires are inflated to 30-35 P.S.I.
Tip
the trailer frame onto its rear end.
Nomad™: With the quick-release lever in the “OPEN” position, insert the wheel
axle assembly completely into the hollow trailer axle, making sure that the
horizontal shaft goes all the way into the axle. Once the wheel is fully seated
in the hollow axle, position the quick-release lever so that it is aimed to the
rear of the trailer in the “CLOSED” position (the lever is marked for OPEN or
CLOSED positions). Repeat
for the other wheel.
BURLEY TRAILER OWNER’S INSTRUCTION AND SAFETY MANUAL
Make sure the wheels are held securely; you should not be able to rock or
shift them. Do not operate with tires inflated above 35 P.S.I. Improperly installed wheels or over-inflated tires can cause an accident or serious injury.
Installing the Side Rails
Nomad™: Flip the four plastic (C-shaped) side
panel hold-downs to the outside. Slide each
side rail down over the side rail guides at the
front and rear of each side of the main frame.
The narrower end of each side panel goes to
the rear, with the “Burley” logo facing outward.
Snap the plastic side panel hold-downs over the
side panel tubing at the front and rear of each
side as shown.
Side
Panel
Hold-down
(snapped
in place)
BURLEY TRAILER OWNER’S INSTRUCTION AND SAFETY MANUAL
Installing the Tongue for
the Nomad™
WARNING
All four side panel hold-downs must be snapped in place before using the
trailer. Otherwise, the side rails can shift or collapse, resulting in the loss of cargo.
Installing the Tailgate and Splashguard
Nomad™: Thread the rear tie-down straps through the inner and then outer
slots of the male buckle sections of the rear side release buckles, which
are attached to the female buckle
sections on the inside rear of the
side panels. Allow enough slack so
B-tab
you can loop the webbing straps
over the rear of the side panels. To
attach the front splashguard to the
front of the side panels, repeat this Tailgate
step using the front tie-down straps
and the front side release buckles.
To accommodate different sizes of
cargo, tighten or loosen the webbing straps as required (see illustration).
Installing the Roll Bar
and Cover
Trailer Frame
Splashguard
Nomad™: Place the cover, right side out, over the side rails with the
“Nomad” logo at the front of the trailer. Slip a roll bar knob through one of
the grommets on the cover. Slide the
roll bar through the casing in the top
of the mesh divider. Align one end
of the roll bar with its corresponding
hole on the side rail. Thread the
roll bar knob through one side rail,
and tighten it into the roll bar (see
illustration). Repeat this step for the
roll bar knob on the other side. Pull
the B-tabs down and loop the rubber
O-rings over the trailer frame. Make
sure the cover extends over the top
of each side panel.
BURLEY TRAILER OWNER’S INSTRUCTION AND SAFETY MANUAL
Tip the trailer onto its back end.
Slide the tongue onto the pivot
pin at the left front. Remove
the hairpin cotter and lock pin
from the front tongue receptacle,
rotate the tongue up into place,
and snap it into the two plastic
tongue receptacles. Push the lock
pin fully into the front tongue
receptacle. Rotate the lock pin
and locate the hole in it, between
the receptacle and the trailer
frame. Anchor the lock pin by
inserting the hairpin cotter all the
way into the hole in the lock pin.
1. Slide
Tongue
onto
Pivot Pin
4. Anchor Lock
Pin with
Hairpin Cotter
2. Rotate Tongue
into Place
3. Anchor Lock Pin
with Hairpin Cotter
5. Lock Pin and Hairpin
Cotter Locked in Place
(viewed from underside)
WARNING
Never operate the Nomad™ trailer without tongue lock pin and hairpin
cotter locked in place. An unlocked tongue can loosen or detach and
cause an accident, resulting in serious injury.
Installing the Tongue for the Flatbed™
Rotate the tongue up into the plastic tongue
receptacle at the front frame. To lock the
tongue in place, slip the retaining pin
through the hole in the tongue receptacle
and close the pin (see illustration).
WARNING
The retaining pin must be locked
in place before using the Flatbed™
trailer; otherwise, the tongue could
shift and cause an accident and
serious injury.
BURLEY TRAILER OWNER’S INSTRUCTION AND SAFETY MANUAL
Installing the Safety Flag
Nomad™: Join the two flag pole sections together. Insert the flag pole into the
flag pocket on the inside of the left side panel. DO NOT USE YOUR TRAILER
WITHOUT THE SAFETY FLAG IN PLACE.
Hitching Your Burley to Your Bicycle
The Burley standard trailer hitch was designed to quickly and safely attach
to virtually all types of bicycles. It is attached to the left rear dropout (the
non-chain ring side) of your bicycle.
1. Remove the quick release lever assembly from your bike and set it aside.
2. Line up the hole on the flat side of the hitch upper arm with the left
rear dropout hole.
3. Reassemble the quick release assembly through the hitch and dropout,
but don’t tighten it yet.
4. Slide the hitch receiver end of the tongue between the two hitch side
arms, and line up the holes. The hitch should clear any racks, bags, or
fittings you have on your bicycle. If there is any interference, contact
your Authorized Burley Dealer.
5. Open the retaining pin and insert the pin through the holes.
6. Rotate the pin’s spring clip and close the pin.
7. Now tighten the quick release lever, with the lever pointing to the rear
of the bike. When properly adjusted, you will feel resistance halfway
through closing the lever (when the lever is pointing straight out away
from the bike).
WARNING
The quick release lever must be in the closed position. Do not operate
the trailer without the hitch safety strap properly installed. A dangling
safety strap can contact the spokes and damage the rear wheel or
cause an accident, resulting in serious injury. Inspect the hitch and
tongue frequently for damage or loose fasteners. Interfering parts or a
damaged hitch can cause an accident, resulting in serious injury.
Loading Your Trailer
Maximum trailer load limit for both the Burley Nomad and the Burley
Flatbed is 100 lbs. When placing cargo into the Nomad trailer, keep the load
centered or forward of the axle. Pack the load as low as possible and make
sure items cannot shift around. When loading cargo on the Flatbed, always
ensure that the load is adequately fastened and centered on the trailer floor.
Cargo can be fastened by rope, cargo tie-down cords, netting, or within a
container that is securely fastened to the Flatbed trailer. Do not permit the
cargo to extend past the perimeter of the fabric floor on either side. Objects
loaded too close to the wheels when the trailer is stationary risk catching in
the spokes or interfering with the wheels when the trailer is in motion. The
area in front of the trailer frame must also remain clear to avoid interfering
with the bicycle’s rear wheel. Objects that extend beyond the rear can obscure the reflectors, cause an unstable weight balance on the bicycle’s rear
heel, or contact the ground on uneven terrain. Do not overload the trailer.
8. Wrap the safety strap around the inside of the chain stay twice and then
over the hitch body. Fasten the hook to the D-ring on the underside of the
tongue end.
10
BURLEY TRAILER OWNER’S INSTRUCTION AND SAFETY MANUAL
BURLEY TRAILER OWNER’S INSTRUCTION AND SAFETY MANUAL
11
Safety Checklists
Maintenance and Storage
Before Each Ride:
Tongue Maintenance
o Wheels tightly attached
Lubricate the tongue pivot using a light machine oil once a year for normal
use, and every three months for heavier use—i.e., with frequent tongue removal or when using in wet or salty conditions.
o Tire pressure at 30–35 P.S.I.
o Hitch properly secured with safety strap in place
o Locked retaining pins for tongue
WARNING
o Maximum load 100 lbs. (40 kg. in Europe)
o Bicycle safety check, especially brakes and tires
o Helmet for rider
o Safety flag, roll bar, side rails and cover in place (Nomad)
o Cargo is adequately secured to the trailer
Monthly Checklist
o Inspect tongue and hitch for damage, scratches, or loose fasteners
o Inspect tongue pivot for smooth operation
o Inspect frame tubing and hardware for cracks, damage, or loose parts
o Inspect tires for wear and cracks
o Inspect wheels for trueness and cracks
o Inspect wheel bearings for wear
o Inspect fabric and webbing parts for rips, abrasion, or missing
or damaged hardware
o Contact Authorized Burley Dealer for repairs/replacement of any
damaged or worn-out parts
Do not use or store the trailer at temperatures below 32˚ F (0° C), as
the hitch rubber flex connector can become brittle and possibly break,
causing an accident resulting in serious injury.
Fabric Care
Your trailer body is made of a tough, waterproof polyester fabric, which is
highly resistant to fading. It can be easily cleaned with any mild soap or
detergent and warm water. For heavy soiling, use a nylon bristle brush. Do
not use bleach for cleaning, as it will damage the fabric. The fabric is an
important part of your trailer’s structure. Replace any fabric that is ripped,
scuffed, or otherwise damaged. Polyester fabric will eventually fade, especially when exposed to direct sunlight. To extend the life of your trailer, wipe
it dry (to help avoid mildew) and store it out of direct sunlight in a dry, wellventilated area.
WARNING
A trailer with damaged or ripped fabric components can allow the
cargo to be lost or cause an accident, resulting in serious injury.
Replace damaged components immediately.
12
BURLEY TRAILER OWNER’S INSTRUCTION AND SAFETY MANUAL
BURLEY TRAILER OWNER’S INSTRUCTION AND SAFETY MANUAL
13
Nomad™ Parts List and Diagram
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(4)
(1)
(1)
(2)
(2)
(2)
(1)
(1)
(2)
(2)
(1)
(2)
(1)
(1)
(1)
(1)
Preassembled Main Frame Assembly
Front Main Frame, 1” Aluminum Tube
Rear Main Frame, 1” Aluminum Tube
Left Frame, 1” Aluminum Tube
Right Frame, 1” Aluminum Tube
Bag Holder, 3/4” Aluminum Tube
Axle Assembly
Fabric Bottom Bag
Front Tongue Receptacle, Plastic
Rear Tongue Receptacle, Plastic
Side Panel Hold-Down
Lanyard w/Lock Pin and Hairpin Cotter to Hold Tongue
Pivot Pin for Tongue
Front Side Rail Guide
Rear Side Rail Guide
Rear Reflector Assembly
Roll Bar, 3/4” Aluminum Tube
Mesh Pocket Panel
Roll Bar Knob
Side Panel
2-Piece Safety Flag
16” Alloy Spoked Wheel, Tire, & Tube Assembly
Tonneau Cover
Tongue Assembly
Hitch
Hitch Safety Strap
23
21
19
17
18
20
16
15
14
4 10
3
13
5
7
12
2
9
1
Optional Accessories (not shown):
Nomad Carry Bag
Nomad Cargo Rack
8
6
11
24
22
26
25
14
BURLEY TRAILER OWNER’S INSTRUCTION AND SAFETY MANUAL
BURLEY TRAILER OWNER’S INSTRUCTION AND SAFETY MANUAL
15
Flatbed™ Parts List and Diagram
Note: Inquire for additional parts.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
(1) Preassembled Main Frame Assembly
(1) Front Main Frame, 1” Aluminum Tube
(1) Rear Main Frame, 1” Aluminum Tube
(1) Left Inner Frame, 1” Aluminum Tube
(1) Right Inner Frame, 1” Aluminum Tube
(4) Wheel Dropout
(1) Inner Frame Bridge
(4) Side Rail Posts
(2) Side Rail, 3/4” Aluminum Tube
(1) Tongue and Hitch Assembly
(1) Tongue, 1 1/8” Aluminum Tube w/Bushing, Spindle & Dropout
(1) Hitch
(1) Hitch Safety Strap
(1) Clip & D-Ring
(1) Rubber Flex Connector
(1) Tongue Receptacle, Plastic
(1) Software Fabric
(2) Reflector Bracket
(1) Rear Casing Anchor Strip
(1) Hardware Bag (not shown) containing:
(2 pair) Tie-down Straps
(2) Rear Reflector with Self-Tapping Screw
(2) Wheel Quick-Release Levers (not shown)
23 (4) D-Ring attachments
24 (2) 20” Alloy Spoked Wheel, Tire and Tube Assembly
16
BURLEY TRAILER OWNER’S INSTRUCTION AND SAFETY MANUAL
BURLEY TRAILER OWNER’S INSTRUCTION AND SAFETY MANUAL
17
Burley Trailer Limited Warranty
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 owner
of a Burley trailer must present the trailer for repair at an Authorized Burley Dealer, together 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 Burley product, and there are no oral agreements or warranties collateral to or affecting
this agreement.
This warranty gives you specific legal rights and you may also have other rights which vary from
state to state.
18
BURLEY TRAILER OWNER’S INSTRUCTION AND SAFETY MANUAL
Copyright ©2007 by Burley Design, LLC
“Burley” is a registered trademark of Burley Design LLC
Burley Design, LLC • 4020 Stewart Rd • Eugene, OR 97402
541.687.1644 • Fax 541.687.0436 • www.burley.com
170007 nomad-flatbed manual r0 rev. 02/07
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