SPITFIRE ALUMINIUM BOAT TRAILER USER & MAINTENANCE MANUAL

1. SPITFIRE ALUMINIUM BOAT TRAILER U SER & M A INT EN AN C E M AN UAL

2. SPITFIRE ALUMINIUM BOAT TRAILER USER & MAINTENANCE MANUAL Thanks for your interest in a SPITFIRE ALUMINIUM BOAT TRAILER and your decision to buy one. We are here to help you get the best out of these unique trailers. Our trailers are not mass produced – rather hand assembled and configured from high quality materials we have sourced from long-standing manufacturing and design partners. All trailers designed in-house and subject to external / 3rd party independent engineering certification. Our compliance with this certification, coupled with full conformance with national Australian Standards for trailers, underpins our confidence and assurance in the trailer we have built for you. This manual is a guide for the care and maintenance of your trailer. We encourage you to review the contents and familiarise yourself with the suggestions and cautions that will also help us help you to have a happy boating experience with us. Data or illustrations in this manual are of a generalised nature and need to be considered in the context of your specific trailer and how you are utilising it. Because every trailer is used differently we cannot guarantee that recommendations and suggestions we make will absolutely apply in your circumstances. However we are confident that this manual provides sufficient guidelines for you to maximise your enjoyment of your new SPITFIRE Trailer. Please contact us as noted below or via our head office directly if you have any questions. Spitfire Trailers 2 Spitfire Aluminium Trailer - User and Maintenance Manual Ver 10

3. Safe Operation: Ensure that the following are in place before towing your trailer: • The tailer coupling should sit firmly and completely on the tow ball. • Trailer safety chains are safely secured to tow bar via rated ‘D’ shackles. A padlock must not be used in conjunction with a safety chain while the trailer is being towed. • Wheel nuts are properly tightened. • Your boat is properly secured to the trailer, perhaps using tie-down straps at the transom end. You also require a safety chain at the winch end in addition to the winch security. Do NOT use a chain and turnbuckle combination to create a rigid tie-down the bow of the boat on our Aluminium Trailers. It is very important to allow the chassis of an Aluminium trailer to flex to release stress – unlike a steel trailer which requires rigidity. A securing chain can be used but must be left slightly loose and alternatively a rope with some ‘give’ can be used. • Your load is within maximum carrying capacity - boat + trailer + on-board fuel and contents must not exceed the stated ATM of the trailer. • Tyres are properly inflated - Check the recommend tyre PSI on the sidewall for correct inflation pressure. • All lights are working. • For braked trailers, the Brake fluid level is sufficient. Warranty All Spitfire Trailers are covered by Warranty for 12 months from the date of purchase. The chassis is warranted for 2 years. The Warranty period starts on the date the trailer is first delivered. Spitfire Aluminium Trailer - User and Maintenance Manual Ver 10 3

4. Warranties apply for… • Spitfire Parts (Labour is return to place of purchase or fitted yourself where applicable and practical) • External items purchased by Spitfire for fitting to a trailer, if warranted by that supplier • Licenced use of the trailer for the intended purpose, and in compliance with the rated ATM Warranty is not provided for… • Wear, tear, and deterioration through normal use, and in particular for items such as tyres, brake linings, wheel bearings, seals, coatings, and wear surfaces • Damage due to or caused by: • Neglect, Negligence, and misuse • Rough/4WD track use • Use of Accessories not approved by Spitfire (eg Boat Catches, L&R, etc) • Non-approved chassis or frame modifications, or additions Regular Maintenance Trailer washing • After use of the trailer it is always recommended to wash it thoroughly with fresh water. Even though your SPITFIRE trailer is anodised and uses only Stain less Steel components, fixtures, and fittings apart from the axle components a good wash is always advisable for long term presentation and service. • • The chassis and component design allows water to disperse freely and there are no drain holes or the like that need to be maintained. For easy and convenient washing of key areas, we have developed a SPITWASH system that connects to your garden hose – we are happy to quote this if required. 4 Spitfire Aluminium Trailer - User and Maintenance Manual Ver 10

5. Rust and Corrosion - Trailer As we will have discussed with you and illustrated when you first considered a Spitfire Aluminium Trailer, we intend that our Alloy/Stainless trailer chassis will last a long time – significantly longer than traditional Steel trailers. Our hope is that you will not need another trailer. To achieve this we take every care in the manufacturing and assembly processes to mitigate against the onset of rust and corrosion. We do this in many ways not the least of which is by utilising long lasting materials of construction, and applying coatings and protections including Anodising, Galvanising, Dacromet, Tefgel, Penetrol, Epoxy paints, etc as barriers between surfaces of different metals. Nevertheless corrosion will occur and vigilance and attention when needed is an important part of extending trailer life. Rust and Corrosion - Axles The most exposed item to rust and corrosion on our trailers is the axle assembly (including the axle tube, swing and stub shafts, hubs, etc). These are made of steel and will show early signs of rust despite having galvanised, dacromet, or painted coatings. What you might see is not harmful and we expect the life of the axles to be at least 7 to 10 years hopefully longer – before perhaps needing replacement. As above, we recommend steps to be taken to extend the life and mitigate against the formation of any damaging rust. We recommend at least the occasional (re-)application of preventative maintenance coatings such as liberal application of heavy fish oil or even the periodic repainting of axles ends with Wattyl Kill-Rust primer and top coat. Wobble Rollers Our wobble rollers are fitted with Stainless steel shafts. On no account should any lubricant be added to the rollers all they need is a good wash with a hose Spitfire Aluminium Trailer - User and Maintenance Manual Ver 10 5

6. Winch bearings/bushes/webbing An occasional spray of lanolin or similar lubricant on the bronze bushes and on the gears will keep the winch operating properly. A periodical check of the condition of the webbing is recommended, especially at its connection to the winch spool and hook. Wheel nuts We recommend that wheel nuts are checked for being tight within the first 100km of trailer use, and then perhaps every 1000km or 3 months thereafter. Trailer wheels require a wrench drive with a thin wall deep socket # 19 and the spare a # 21. A standard wheel brace is too think to access the nut inside the rim. We do not use any anti-seize grease on wheel nuts. These are also the only items on our trailers that may be subjected to a rattle gun. Spitfire bearing and seal specs are listed below: SPITFIRE BOAT TRAILERS - TORSION AXLE BEARINGS & SEALS Taper Bearings Rotary Shaft Oil/Grease Seals Axle Sizes (Neoprene Double Lip Seal with garter spring For Boat Trailer hubs/Seawater environment) (Neoprene Double Lip Seal with garter spring For Boat Trailer hubs/Seawater environment) Large : LM67049A/LM67010 Small : LM11949/10 OD x ID x Depth (mm) 62 x 38 x 10 Unbraked AXLES: 750kg Bearings: Seal (Double Lip, NBR, Single Spring, TC) AXLES: 1200kg, 1500kg, 1800kg (2019 and 2020 Model trailers) Large : L68149/10 Small : LM12749/10 OD x ID x Dept (mm) 62 x 44 x 10 Seal (Double Lip, NBR, Single Spring, TC) AXLES: 1200kg, 1500kg, 1800kg (2021 Model trailers with DEEMAXX Brakes) Large / Inner: L68149/11 Small / Outer: L44649/10 OD x ID x Dept (mm) 65 x 44 x 10 Seal (Double Lip, NBR, Single Spring, TC) AXLES: 2100kg (2021 Model trailers with DEEMAXX Brakes) Large / Inner: 25580/20 Small / Outer: 15123/245 OD x ID x Dept (mm) 85,7 x 57 x 10 Seal (Double Lip, NBR, Single Spring, TC) Seal (Metric) : 57 x 85,7 x 10 mm Seal (Imperial) : 2 1/4 x 3 3/8 x 3/8 AXLES: 2700kg (2021 Model trailers with DEEMAXX Brakes) Inner: 25580/20 Outer: 15123/245 Bearings and grease seals available from SPITFIRE BOAT TRAILERS 6 Spitfire Aluminium Trailer - User and Maintenance Manual Ver 10

7. Wheel bearings, Bearing Buddy Lubrication, and EZ- Lube system All wheel bearings require periodic maintenance and checking. Convention is that bearings should be replaced seasonally however we feel there are many variables and therefore regular checking should be undertaken in the first instance (at least 6 monthly) to establish a suitable pattern applicable to your trailer – and also to monitor the integrity of the grease and seals. We recommend kicking the tyres prior to every use to quickly check for any looseness in the wheel. At the same time we suggest monitoring the wheel hub temperature (by hand or with a thermometer) whenever you get to a destination. Any hub that feels significantly warmer than the others will be worth checking further. Maintenance requirements vary considerably with the type and frequency of trailer use and therefore clients need to learn what is appropriate maintenance for their own circumstances. If your trailer is fitted with our EZ Lubrication system then the purge of this system is effective in monitoring the grease while also ensuring effective greasing of the bearings. Purged grease will easily show up any obvious grit or water contamination, or grease that appears to have been heat affected. These are good indicators that bearings and seal to be checked more closely – and perhaps replaced. So as not to ‘pop’ the inner seal, it is imperative to jack up the wheel and keep it rotating while pumping grease into the EZ system. A convenient position either near the wheel and under the axle, or under the chassis rail, can be used as the jacking point. As previously noted Maintenance requirements vary considerably with the type and frequency of trailer use and therefore clients need to learn what is appropriate maintenance for their own circumstances. Your bearings and seal specifications are available from SPITFIRE. For grease we recommend any good quality marine bearing grease be used with a tackiness and water repellent characteristics. Note: Each time trailer is put into water or six (6) monthly which ever comes first, the grease should and can be quickly replaced via the ez system to clean out contaminated grease and ingrese water Spitfire Aluminium Trailer - User and Maintenance Manual Ver 10 7

8. IMPORTANT: Adding Grease to bearings process (HOW TO) 1. Remove decorative cap by undoing 2. Stainless allen key bolts 2 remove rubber grommet to expose grease nipple 3. Pump a liberal amount of high temperature bearing grease minimum 10- 15 pumps, Rotate the wheel as you are adding grease and continue until you see grease pushing out front seal. Wipe away excess grease. 8 Spitfire Aluminium Trailer - User and Maintenance Manual Ver 10

9. 4. Ensure rubber grommet is replaced properly failure to do so will allow water inside hub and also cause rusting issues and loss of grease 5. Replace decorative cap 6. Always check for heat in hubs especially on longer trips using temp gun supplied 7. Regular inspection and adjustment of bearings is recommended every 400-500kms Nuts and bolts All nuts used on the trailer are Stainless Steel 316 M12 NYLOC. And, as the trailer has been hand-assembled, it is recommended to periodically check that nuts are firmly tightened – especially those holding the axles, cross members, and drawbar to the chassis. If any Stainless steel nuts are replaced, an anti-galling grease needs to be applied to the bolt thread. Chassis nuts are torqued to 40nm during assembly and should not need to be fastened beyond this. On no account should rattle-guns be used on a SPITFIRE trailer because the torque cannot be effectively monitored. Chassis bolts done up too tight will unnec- essarily distort and damage the chassis rails. Trailer Brake calliper bolts are torqued to 52nm. Do NOT overtighten the nuts securing the lights to the light brackets. Overtightening will damage the light backing plate and potentially cause a leak into the housing. Spitfire Aluminium Trailer - User and Maintenance Manual Ver 10 9

10. Trailer wheels and Spare wheel nuts Trailer wheels and the spare wheel require 19mm and 21mm long thin wall sockets respectively, to be used for removal. The 21mm socket for the spare tyre is sometimes inconvenient – however we use this system as a deterrent for casual theft of the machined alloy spare wheel. Torsion Axles – Wear parts SPITFIRE trailer torsion axles do not require any maintenance for moving or wear parts. A replacement may be required many years down the track on account of possible corrosion of the steel parts as previously discussed. The axle replacement cost is much less than the equivalent maintenance and repair costs of spring axle systems over the same time period. Hydraulic Brakes – up to 2000kg ATM All braked trailers up to 2000kg utilise a mechanical override cou- pling which drives the hydraulic braking system via a momentum activated piston. There is an adjustment screw on the coupling brake lever that determines the response time and response strength of the trailer braking. If there is a feeling that the trailer is either braking too soon or too hard or otherwise not at all then please check the gap between the head of the adjustment screw and the back of the coupling piston. In the static position, there should be approximately 10mm gap. Brake Fluid used on delivery is a DOT4 10 Spitfire Aluminium Trailer - User and Maintenance Manual Ver 10

11. Hydraulic Brakes – over 2000kg ATM Most SPITFIRE trailers over 2000kg ATM will be fitted with the ALKO iQ7 Brake Actuator system. This is powered via a 50 amp Anderson plug (30 amp fuse) and controlled via a control cable connected to Pin #5 in the 7-pin trailer electrical connection. It is important to make sure that the Anderson Plug will not disconnect from the tow vehicle during towing, as this action will activate the trailer break-away system and lock the trailer brakes assuming a separation of the trailer from the tow vehicle. A periodic check of the brake fluid level in the ALKO iQ7 can be done via the sight-glass on the ALKO. If a fluid top-up is required, then please use a DOT4 brake fluid. On disconnection of the ALKO from the car the trailer brakes will lock up under pressure applied by the ALKO unit. To move the trailer and also for parking the brake pressure needs to be released. Do not leave the trailer parked with the brakes pressurised. Instead chocks are to be used unless the trailer is otherwise restrained. BEWARE: The trailer has no mechanical hand brake and when the brakes are de-pressurised, the trailer will be unrestrained. If you’re on anything but level ground, please place chocks under the trailer wheels before de-pressurising the brakes. Spitfire Aluminium Trailer - User and Maintenance Manual Ver 10 11

12. DEEMAXX Brakes From our 2021 model axle systems onwards we utilise DEEMAXX brakes on all our trailers. The DEEMAXX callipers contain stainless steel pistons and cylinders, while the Calliper housing and rotor discs are made in either steel with a Dacromet coating or other- wise Stainless Steel 304. There is no maintenance required other than a periodic check of the brake pads and also the integrity of the brake lines. However, as with all components on a Boat trailer, regular washing with fresh water is always beneficial. Fitting your boat to the trailer Spitfire Aluminium Trailers are not rigid structures like Steel trailers. And therefore, setup requires particular steps, taking into account the flexing of an Aluminium chassis; Steps are: 1. 2. 3. 4. 5. 6. 7. Position the boat as required on the trailer to achieve a suitable tow ball weight Move axles if necessary Level the trailer Adjust rollers and bunks to suit boat Adjust winch post to suit the bow and fastening of the boat Cut excess post length Boat tie-down You will need: A trolley jack, two jack stands, some thick pieces of timber, a spirit level, tape measure, 19mm sockets and spanners 1. Ensue the trailer is on a reasonably level surface. Place the boat on the trailer so that bottom of the transom lines up with the back of the trailer chassis – or sits just over rear rollers or just inside rear bunks. If this is an inconvenient position due to transom sensors, bait tank pickups, stabilizers, or other accessories, then move the boat to a convenient position. Bear in mind the winch post and possible limitations in setting its position too if the boat is moved too far back or forwards on the trailer. 12 Spitfire Aluminium Trailer - User and Maintenance Manual Ver 10

13. 2. Now measure the tow ball weight. It needs to be between 7.5% and 10% of the total trailer load. A 2000kg trailer should have a tow ball weight of 150 to 200kg during normal operation. If the tow ball weight is not achieved by convenient boat positioning, then the axles will need to be moved forwards or backwards to suit. Moving the boat forwards or backwards by a measured amount (say 100mm) and then re-measuring tow ball weight, will indicate quickly how much axle movement will make a suitable difference to final tow ball weight. 3. Levelling the trailer: Once the boat position has been confirmed and tow ball weight in a suitable range, the following steps need to be taken to level the chassis prior to adjustment of any rollers or the drawbar: a) Make sure the boat is centred on the trailer. It’s a good idea to mark a centre line between the chassis rails at the stern and make sure the rear bung on transom (or some other reference point) lines up with this. Jack up the drawbar (via jockey wheel or trolley jack) so that the trailer is lifted above horizontal at the front. Place a jack stand under the chassis on either side just after of the chassis curve, and with the stands adjusted to the underside of the chassis. Lower the drawbar to let the stands take the weight of the trailer. b) Spitfire Aluminium Trailer - User and Maintenance Manual Ver 10 13

14. c) Using a spirit level, continue to lower the drawbar until the level of the drawbar measures the same level as the main chassis section ( after of the jack stands) 4. Adjusting Rollers and bunks Place the spirit level onto a convenient spot on the transom or rear of the boat that best allows measurement of the horizontal. When adjusting rollers and bunks on either side of the boat, do not lift the boat past the horizontal. a) Start with bunks or rollers from the front or rear, adjusting them so that they line up with strakes or suitable positions under the hull. In general you want the side hull supports placed as wide as reasonably possible. Adjustment up should be just enough to stop the hull flipping from side to side. It is not appropriate to take the weight of the boat with these adjustments if the keel is resting on keel rollers or our HDPE keel slides. b) Use the trolley jack to assist vertical placement of the adjusted rollers or bunks. c) Be sure to check that the boat is remaining horizontal after each adjustment. 14 Spitfire Aluminium Trailer - User and Maintenance Manual Ver 10

15. 5. Adjusting the winch post This is the last item to be adjusted. At this point the boat should still be on the jack stands. Our preferred adjustment on any trailer is for the winch roller to sit BELOW the bow eye / winch hook. The winch bracket and winch webbing should be positioned so that the webbing is horizontal when pulling the boat onto the trailer The safety chain will then follow a short path to the eye hook. Where the positioning of the winch bracket (with its winch roller BELOW the bow hook on the boat) is not possible (eg due to use of a boat latch or similar device), a customised solution for fitting will be required. (See warranty ) See below: If this is the case, please contact your Spitfire Dealer for more advice. In the setup of any customised winch arrangement it is very important that the winch rope/webbing will be pulling in a horizontal line from the spool to the hook at the bow of the boat. Once the winch post has been adjusted, then the jack stands can be removed. The chassis should be level along its length after this process. Spitfire Aluminium Trailer - User and Maintenance Manual Ver 10 15

16. 6. Cutting off the excess length of the roller and bunk posts Sometimes there is length of roller or bunk post that needs to be cut off once the boat has been fitted. Mostly this occurs with shallow-VEE hulls but can also occur if the rollers and bunks can’t for some reason be positioned wide – ie close to the chassis rails. When cutting, we suggest you leave approximately 50mm of post below the bracket for any unforeseen future adjustment. 7. Tie Down A boat that is properly set up on the trailer, having a suitable tow ball weight, fixed at the bow with the winch and a safety chain, and fixed at the rear with straps. Extra safety tie downs can be could be used on larger boats. But if an additional tie is desired at the bow then please note the following; Your new Spitfire Aluminium boat trailer is NOT a steel trailer or a pretend Aluminium trailer with a steel drawbar. Aluminium needs to be able to flex to relieve stress. Whereas steel must be kept rigid otherwise it will suffer fatigue. We strongly recommend you do NOT use your steel trailer tie-down (eg rigid chain and turnbuckle) on your new Aluminium trailer. If a tie-down is desired, then please use a rope or something with some ‘give’ in it. If its for safety, then perhaps also a chain can be used but ensure it is not pulled tight. Lights & Wiring All Spitfire trailers use Submersible LED lights for both the rear lights and side clearance lights mounted on the mudguards. The following are integrated into the rear light unit; • • • Parking, Number Plate, and Brake light (inside) Indicator Light (middle) Reversing Light (outside) In earlier trailer models the wiring loom fastens to the light with a Bayonet connector which also integrates connections for the side mudguard clearance lights. In later models the wiring is continuous from the rear and side clearance lights to connections in the front of the trailer – and stored in the drawbar. 16 Spitfire Aluminium Trailer - User and Maintenance Manual Ver 10

17. Lights & Wiring Wiring of the earlier trailers is as flows: • • Green and Yellow = Left & Right Indicators Brown and Black = Tail Light, Reverse Light and Mudguard Clearance lights Blue = Electric Brake Controller Alko Models White = Earth Red = Brake Lights • • • Note: Pin # 5 in a 7 Pin Plug is usually a blue wire used for a service brake control. Do not confuse the blue wire in these earlier Spitfire wiring looms with a service brake. And in addition, a black wire is usually for a reversing light. Do not confuse the black wire in these earlier Spitfire wiring looms with a reversing light All wiring of the solid wire type (ie no bayonet connected lights) conforms to Australian Standard colour connections. Service At our workshop we have full service capability and can support your trailer as required. We wish you happy boating and thank you again for your interest in a Spitfire Boat Trailer! It is your responsibly to keep track of your service intervals and when its required, many parts require greasing and maintenance to be preformed and pre started before every trip should be done and during each trip and after. Spitfire Aluminium Trailer - User and Maintenance Manual Ver 10 17

18. SPITFIRE DISTRIBUTORS AUSTRALIA Spitfire Trailers Townsville - 15 Leyland St, Garbutt Spitfire Trailers Brisbane - 617 Toohey Rd, Salisbury Spitfire Trailers Adelaide - Angle Park, Adelaide Spitfire Trailers Sydney - 3-10 Ponderosa Parade,Warriewood Spitfire Trailers Perth - 3-30 Salpietro St, Bibra Lake 1300 483 115