DK2 MMT5X7 Series 5 X 7 ft Utility Trailers
NOTE: If you find any damaged or missing parts please call Marlon® Customer Service or contact us via our website. We will replace any damaged or missing parts to you for free. Please do not return to the store.
TECHNICAL SPECIFICATIONS
- PAYLOAD CAPACITY: 1,639 lb (743.4 kg)
- GVWR: 2,073 lb (940.3 kg)
- WHEELS & TIRES D.O.T.: 5.30-12 6-ply bias tires with 5 x 4.5” (11.4 cm) bolt pattern
- MATERIAL: Fully welded heavy-duty UV powder coated tubular steel
- SIDE PANELS: Corrugated reinforced steel
- DROP GATES: 24” (61 cm) load-bearing corrugated reinforced steel
- FLOORING: Corrugated reinforced steel panel
- DUMP BED: 2-position, axle-mounted with quick-release lock pin
- LIGHTING: Pre-wired, quick-connect D.O.T LED
- BED DIMENSIONS: 88” (L) x 52” (W) 223.5 cm (L) x 132.1 cm (W)
- FLOOR HEIGHT: 20” (50.8 cm)
- HITCH HEIGHT: 16” (40.6 cm)
- DIMENSIONS: 177” (L) x 65” (W) x 36” (H) 449.6 cm (L) x 165.1 cm (W) x 91.4 cm (H)
- WEIGHT: 434.3 lb (197 kg)
- SHIPPING DIMENSIONS: 88” (L) x 55” (W) x 9” (H) 223.5 cm (L) x 139.7 cm (W) x 22.9 cm (H)
- SHIPPING WEIGHT: 458.6 lb (208 kg)
- WARRANTY: 1-year limited
SAFETY
SAFETY CONVENTIONS
- DANGER! This indicates a hazardous situation, which, if not avoided, could result in death or serious injury.
- WARNING! This indicates a hazardous situation, which, if not avoided, could result in minor or moderate injury.
- CAUTION! This information is important in proper use of your machine. Failure to follow this instruction could result in damage to your machine or property.
ADDITIONAL INFORMATION AND POTENTIAL CHANGES
We reserve the right to discontinue, change, and improve our products at any time without notice or obligation to the purchaser. The descriptions and specifications contained in this manual were in effect at printing. Equipment described within this manual may be optional. Some illustrations may not be applicable to your machine.
IMPORTANT SAFETY CHECKLIST
Trailers are generally not used everyday. Your trailer may sit for extended periods of time between uses making it very important to check all components thoroughly before each use. Following these simple instructions will maximize the life of your trailer and help you safely transport cargo.
CAUTION! DO NOT ABUSE THE TRAILER: Trailer performance is best if you follow the guidelines set forth in this manual. Do not force the trailer to do a job it is not designed for. Know your trailer; learn its applications and limitations.
- Make sure the towing vehicle as well as the hitch are capable of towing the trailer. Check your vehicle owner’s manual for trailering things.
- Inspect the trailer and all of its parts before each use.
- Check the operation of all lights. Operating lights are mandatory on a trailer.
- Check to ensure wheel bolts are tight. Torque to 80 ft.-lbs. Re-tighten after the first 50 miles (80km).
- Check the tire pressure. Maximum 80 PSI (550 KPA) when carrying the maximum rated load.
- Re-pack the wheel bearings every 2,000 miles (3,200km) or a minimum of once every year.
- Check that the trailer coupler is fastened securely onto the trailer ball. The trailer ball must be a 2-inch ball.
- Make sure the safety chain is attached to the trailer and the towing vehicle.
- If your trailer has an optional side kit, make sure all bolts and pins are in place before transporting your trailer.
- Do not exceed the Gross Vehicle Weight Rating (G.V.W.R.) which is shown on the trailer serial/certification label.
- Balance and secure the load on the trailer. See “Trailer Loading” section in this manual.
- Lubrication of the coupler, springs, and the tilt mechanism should be done periodically to stop corrosion and keep parts moving freely.
DANGER! KEEP CHILDREN AWAY: Be sure children are kept a safe distance from the trailer operating area.
DANGER! NEVER SIT OR RIDE ON THE TRAILER: Serious injury or death could occur.
- DANGER! EXERCISE EXTREME CAUTION WHEN TILTING THE TRAILER: There are many areas of the trailer where injury can occur if used improperly. The trailer may tilt quickly and unexpectedly during the loading and unloading process. The tilt option should not be used for heavy loads.
- DANGER! Ramps should be used for loading heavy items.
- DANGER! Do not drive with the trailer in the tilted position.
- DANGER! Do not load more than one all-terrain vehicle onto this trailer.
- DANGER! If the trailer is incorrectly attached to the vehicle, it could pull away from the vehicle and fall off.
- DANGER! Secure the trailer to the towing vehicle before transportation. Make sure coupler is locked and the safety chains are attached to the trailer and the vehicle.
- DANGER! Secure your cargo into the trailer properly and in compliance to local laws.
- DANGER! When driving do not exceed the speed limit. Braking time can be considerably longer when a vehicle is towing a loaded trailer.
- DANGER! Any modifications made to the trailer or parts of the trailer will void the trailer warranty and release Marlon® Recreational Products Ltd. of any responsibility for damages, injuries or accidents incurred.
LIGHTING & WIRING MAINTENANCE
DANGER! USE ONLY ORIGINAL EQUIPMENT PARTS AND ACCESSORIES: Consult Marlon® at 1 888-277-6960 for the recommended accessories. The use of improper accessories may cause hazards or injuries.
WIRING LEGEND
| WIRING LEGEND | ||||
| SYMBOL | COLOR | DESCRIPTION | OPERATION | |
| G | Green Wire | Passenger Side (Right) | Right Signal | Brake |
| B | Brown Wire | Running Lights | Tail Light Marker | Yellow Front Side Markers |
| Y | Yellow Wire | Driver Side (Left) | Left Signal | Brake |
| W | White Wire | Ground | Trailer Ground | |
NOTE:
Brake light goes out on the side that is signaling. Lower Filament (Brighter light) = Brake & Signal. Higher Filament (Dimmer Light) = Running Lights
TO TEST THE VEHICLE WIRING:
You will need a 12v light tester. Attach the wire clamp of the tester to the ground wire on the vehicle plug. Then touch the tester pin into one of the vehicle plug contacts. Turn on the corresponding vehicle operation i.e. Running Lights. This will illuminate the tester light if the vehicle wiring is correct. Follow this same procedure for the signal and brake lights.
TO TEST THE TRAILER WIRING:
Once you have confirmed that the vehicle trailer plug is operating properly, connect the trailer plug into your vehicle. To proceed to test each of the lights and power leads using your 12v light tester. Follow the wiring legend and diagram to test each corresponding wire for power when the trailer light is not operating.
CAUTION! Always be sure to check your brake, running and signal lights before each use. Make sure that all of your connections are solid and that all wiring is in good condition.
CAUTION! Bare, stripped, or pinched wire will cause a short in the trailer, which will cause the vehicle fuse to blow. A solid ground is required for your lights to work properly. All contacts must be to bare metal. Light covers should be well maintained and kept clean. Be sure that your lights are always visible, not obstructed by your load.
LOADING YOUR TRAILER
- Distribute the weight evenly.
- Center the load over the axle, keeping about 10% of the weight on the tongue. (If vehicle wheels are not on a crossbeam you will need to add wood to the floor to support each axle.
- Center the load from side to side.
- Always secure your cargo into the trailer properly and in compliance to local laws.
WARNING! Do not build your trailer load higher than 3 feet. Higher loading will affect trailer handling due to increased wind resistance. This may cause violent movements, accidents and serious injury.
WARNING! TRAILER CAPACITY
- Never overload your trailer. Each trailer has a maximum payload that should not be exceeded. Overloading your trailer could cause serious damage to your trailer as well as the towing vehicle. Please refer to your trailer serial/certification label located on the same frame of the trailer for capacity details.
- The Gross Vehicle Weight Rating (G.V.W.R.) is the weight of the trailer + the maximum payload the trailer can carry. The trailer weight and the payload must not exceed this weight rating.
- Be sure that any load carried in your trailer does not extend beyond the frame of your trailer. Never place loads on one side only.
WARNING! TONGUE WEIGHT
- The tongue weight is 10% of the load (this does not include the weight of the trailer).
- The load is divided so that 90% of the load is over the axle and 10% is over the tongue.
TRAILER COUPLER
TO ADJUST COUPLER TO BALL:
Set the coupler and tongue onto the 2-inch trailer ball on your vehicle. Raise the locking lever, push up on the channel lock and turn nut to tighten or loosen the coupler. Proper adjustment is obtained when the coupler is as tight as possible on the ball and the locking lever can still be opened and closed.
CAUTION! Before towing your trailer be sure to check the capacity of your trailer hitch on your vehicle (never exceed this or your trailer’s capacity). The DK2® by Marlon® Trailer is equipped with a 2-inch coupler and must be used with 2-inch trailer ball. Make sure that the trailer ball is completely engaged in the coupler ball.
WHEEL BEARING & HUB ASSEMBLY
NOTE: No parts are more critical for the dependable performance of your trailer than the bearings, races, and seals. To ensure that your trailer performs reliably, you should inspect the bearings, races, and seals and re-pack the bearings every 12 months or 3,200km (2,000 miles). This is easily found on the internet by searching “Trailer Wheel Bearings Maintenance”.
REPACKING WHEEL BEARINGS
- Loosen wheel bolts (do not remove)
- Support trailer so wheel is off the ground (jack stack – floor jack – block)
- Remove nuts and wheel
- Disassemble hub
- Clean hub and pack bearings with wheel bearing grease
- Re-install bearings, nut and cotter pin
WARNING! DO NOT over-tighten nut. The hub must turn freely and without play. - Re-attach bolts and wheel (torque to 80 ft-lbs.)
ASSEMBLY
- STEP 1: UNPACK YOUR TRAILER
- Open and unpack all items. Leave lots of working space as you will need to flip the trailer over later in the assembly.
- The trailer frame is shipped upside down as shown. Leave the frame on the cardboard and use it as your work surface.
- STEP 2: L-BRACKETS & LEAF SPRINGS
- Place springs and tongue tubes as shown – the hub end of the spring faces towards the front of the trailer. Insert the two M14 x 120 mm bolts from inside out through the tongue tube, then the channels, spring hubs, and fender L-brackets on the front. Use the M14 x 85 mm bolts at the back, again inserted from the inside outward, through the channels, over the back tabs on the springs, and the rear fender L-brackets. Install the 4 washers and 6 M14 lock nuts finger tight in the locations shown.
- Place springs and tongue tubes as shown – the hub end of the spring faces towards the front of the trailer. Insert the two M14 x 120 mm bolts from inside out through the tongue tube, then the channels, spring hubs, and fender L-brackets on the front. Use the M14 x 85 mm bolts at the back, again inserted from the inside outward, through the channels, over the back tabs on the springs, and the rear fender L-brackets. Install the 4 washers and 6 M14 lock nuts finger tight in the locations shown.
- STEP 3: COUPLER & SAFETY CHAIN
- Insert the two 1/2” hitch pins as shown.
- Install the coupler and safety chain using the M12 x 75 mm bolts and M12 lock nuts provided.
- Find the middle link on the chain, and feed it through the side of the tongue where the wiring harness is not present. Feed your bolt through.
- STEP 4: AXLE
- Lay the axle across the springs. Mount the axle to the springs with the M10 U-bolts, left spring Plate, M10 washers, and M10 nylock nuts.
NOTE: Insert the raised point on the spring into the concave on the axle. - Make sure that the axle is in the right position.
- Lay the axle across the springs. Mount the axle to the springs with the M10 U-bolts, left spring Plate, M10 washers, and M10 nylock nuts.
- STEP 5: TIRES
- Install the tires. Ensure all ten wheel nuts provided are tightened properly.
CAUTION! The wheel nuts will need to be torqued after the trailer is flipped over and the wheel can be better held.
NOTE: Tapered ends of wheel nuts face inward toward the wheel.
- Install the tires. Ensure all ten wheel nuts provided are tightened properly.
- STEP 6: PRE-WIRING
- The wire harness is pre-assembled under the frame. The pre-assembled wiring harness is pre-mounted on the trailer and must be connected to the harness that goes to the front of the trailer tongue.
NOTE: Make sure all connections are accessible for light mounting when trailer is flipped over. - Mount the light assemblies onto the side of the rear portion of the frame using the M6 square neck bolts, M6 washers, and M6 nylock nuts. Plug the light connector into the wire harness. Mount the side marker onto the side of the front portion of the frame using the self-tapping screws. Plug the light connector into the wire harness.
- The wire harness is pre-assembled under the frame. The pre-assembled wiring harness is pre-mounted on the trailer and must be connected to the harness that goes to the front of the trailer tongue.
- STEP 7: FLIP OVER & FENDERS
WARNING! Rolling the trailer over will require assistance. The trailer at this point weighs an estimated 400lb (181.4kg).- The fenders now need to be assembled. Secure each fender by fastening the nuts and bolts provided with the fender to the L-brackets and the channel that holds the springs in place.
- Once the angle of the L-brackets is established, tighten the 4 M14 bolts through the springs until springs are secure. Do not over-tighten as it will collapse spring channel.
NOTE: The above drawing shows the trailer from below with axle and wheels removed for clarity.
- STEP 8: SIDE PANELS
- Insert and tighten the eight (four on each side) M8 x 20 mm bolts and M8 lock nuts provided.
- Insert and tighten the eight (four on each side) M8 x 20 mm bolts and M8 lock nuts provided.
- STEP 9: LIGHTS
- Install the lights and complete the wiring.
- Mount the side marker onto the side of the front portion of the frame using the self-tapping screws. Plug the light connector into the wire harness.
NOTE: Use dialectric grease on each connector for corrosion prevention.
- Attach the rear light brackets and install light assemblies. Connect light assembly to wiring harness.
- The driver’s side light is one with the clear lenses on the bottom, the license plate bracket needs to be installed on the driver’s side as well at the same time of assembly.
- Attach all necessary wiring and fasten lights to the side of the trailer.
- STEP 10: GATES
- STEP 11: WHEEL TORQUING & INSPECTION
- WARNING! WHEEL NUTS MUST BE TORQUED TO 80 FT-LBS.
- WARNING! Connect to vehicle to confirm all lights are working correctly.
- WARNING! Inspect trailer once more to make sure all steps were completed properly. Remember to re-check all nuts before use to make sure they are all properly tightened.
WARNING! It is the trailer owner’s responsibility to periodically check all hardware is secure and fastened properly.
PARTS & SCHEMATICS
PARTS LIST
| ITEM | DESCRIPTION | PART NO. | QTY. |
| 1 | FRAME | 100-0162 | 1 |
| 2 | RIGHT TONGUE TUBE | 100-0163 | 1 |
| 3 | LEFT TONGUE TUBE | 100-0164 | 1 |
| 4 | 3-LEAF SPRING | 219-0003 | 2 |
| 5 | AXLE ASSEMBLY | 310-0112 | 1 |
| 6 | HUB ASSEMBLY | 310-0078 | 2 |
| 7 | TIRE – 5.30X12C | 220-0019-WH | 2 |
| 8 | FENDER | 206-0036 | 2 |
| 9 | REAR LOADING RAMP | 350-0044 | 1 |
| 10 | FRONT GATE | 100-0161 | 1 |
| 11 | LEFT TAILLIGHT BRACKET | 100-0148 | 1 |
| 12 | RIGHT TAILLIGHT BRACKET | 100-0149 | 1 |
| 13 | SIDE PANEL | 100-0160 | 2 |
| 14 | 2″ COUPLER 2X2 | 204-0003 | 1 |
| 15 | SAFETY CHAIN | 208-0002 | 1 |
| 16 | SPRING PLATE | 100-035 | 2 |
| 17 | FRONT FENDER L BRACKET | 100-0153 | 2 |
| 18 | REAR FENDER L BRACKET | 100-0154 | 2 |
| 19 | LEFT TAIL LIGHT | 205-0023 | 1 |
| 20 | RIGHT TAIL LIGHT | 205-0024 | 1 |
| 21 | AMBER MARKER LIGHT | 205-0069 | 2 |
| ITEM | DESCRIPTION | PART NO. | QTY. |
| 22 | L-PIN | 207-0028 | 2 |
| 23 R CLIP | 207-0012 | 2 |
| 24 D PIN | 207-0012 | 10 |
| 25 LICENSE PLATE HOLDER | 207-0011 | 1 |
| 26 LUG NUTS | 210-0012 | 10 |
| 27 TONGUE FRONT WIRE HARNESS | 205-0070 | 1 |
| 28 FRAME LEFTHAND WIRE HARNESS | 205-0073 | 1 |
| 29 FRAME RIGHTHAND WIRE HARNESS | 205-0078 | 1 |
| 30 M10 X 95 X 38 U-BOLT | 210-0154 | 4 |
| 31 M12 X 80 HEX BOLT | 210-0043 | 2 |
| 32 M10 X 70 HEX BOLT | 210-0029 | 8 |
| 33 M10 X 50 HEX BOLT | 210-0019 | 8 |
| 34 M14 X 120 HEX BOLT | 210-0092 | 2 |
| 35 M14 X 85 HEX BOLT | 210-0018 | 2 |
| 36 M8 X 20 HEX BOLT | 210-0070 | 8 |
| 37 M4 x 65 PHILIPS BOLT | 210-0153 | 4 |
| 38 M12 WASHER | 210-0004 | 2 |
| 39 M14 WASHER | 210-0063 | 4 |
| 40 M10 WASHER | 210-0002 | 24 |
| 41 M8 WASHER | 210-0007 | 8 |
| 42 M12 NYLOCK NUT | 210-0015 | 10 |
| 43 M4 NYLOCK NUT | 210-0108 | 6 |
| 44 M14 NYLOCK NUT | 210-0064 | 6 |
| 45 M10 NYLOCK NUT | 210-0003 | 24 |
| 46 M8 NYLOCK NUT | 210-0008 | 8 |
| 47 REAR LOADING RAMP – DUG MODELS | 350-0044 | 1 |
SCHEMATICS
AXLE ASSEMBLY PARTS & SCHEMATICS
PARTS LIST: AXLE ASSEMBLY
| ITEM | DESCRIPTION | PART NO. | QTY. |
| 1 | AXLE WELDMENT | 300-0075 | 1 |
| ITEM | DESCRIPTION | PART NO. | QTY. |
| 2 | SEAL (25 X 52 X 15) | 217-0019 | 2 |
| 3 BEARING (30205) | 202-0004 | 4 |
| 5 HUB ASSEMBLY | 310-0078 | 2 |
| 6 GREASE FITTING | 229-0083 | 2 |
| 7 DUST CAP WITH HOLE | 229-0067 | 2 |
| 8 RUBBER DUST CAP | 229-0105 | 2 |
SCHEMATICS: AXLE ASSEMBLY
WARRANTY
WHAT IS COVERED
Marlon Recreational Products Ltd. warrants to the original purchaser of a DK2 by Marlon product that the product will be free and clear of manufacturing defects in workmanship and materials under normal use and service for a period of one (1) year from the date of the original purchase. If within one (1) year from the original date of purchase this product fails due to defect in material or workmanship, Marlon will repair, replace, or supply any defective part at our option. Upon expiry of one (1) year, Marlon will have no further liability related to the Product. Marlon does not authorize any party, including its authorized distributors or dealers, to offer any other warranty on behalf of Marlon Recreational Products Ltd.
THIS WARRANTY DOES NOT COVER OR APPLY TO:
- Damage to the product due to misuse, mishandling and abuse.
- Improper installation, maintenance and storage.
- Expendable parts such as blades, teeth, hardware (nuts, bolts, springs, etc.), winch straps, cable or rope (winches), belts, chains, tires, bearings or hub assemblies, dust caps, springs, markers, snow deflectors, and scraper blades (snow plows).
- Normal wear and tear.
- Consequential damage and incidental damages such as damage to persons or property.
REGISTERING YOUR DK2 BY MARLON PRODUCT
Please take a minute to register your DK2 by Marlon product online at www.detailk2.com/warranty or by calling customer service at 1 888-277-6960.
PROCEDURE FOR OBTAINING A RETURN AUTHORIZATION
Within the one (1) year warranty period, the purchaser of the DK2 by Marlon product must notify an authorized distributor or dealer of the claimed defect and provide proof of original purchase. At this time the validity of the claim will be determined and a Return Goods Authorization Number (RGA) will be issued if approved. No returned product will be accepted under warranty unless accompanied by an RGA# issued by Marlon.
RESOLUTION FOR A DEFECTIVE DK2 BY MARLON PRODUCT
Marlon Recreational Products Ltd. will at its option repair or replace the defective product or parts covered by this warranty. The repaired DK2 by Marlon product or parts will be shipped to the purchaser upon completion. All transportation charges shall be the responsibility of the purchaser. Any damage in transit will be the responsibility of the carrier or at the risk of the purchaser.
TRAILER LICENSING
The DK2 by Marlon Trailer Kit MUST BE CERTIFIED after assembly by a local garage which is approved and holds a license to provide safety certificates for roadway vehicles.
In order to register your trailer with the Department of Motor Vehicles or Ministry of Transportation and obtain a license plate you will need to have either the NVIS form in Canada or the Manufacturers Certificate of Origin in the US filled out and signed by the dealer transferring ownership to you. This form is found in your trailer manual package. Take this form along with the bill of sale (cash register receipt) and safety certificate to your local Department of Motor Vehicles or Ministry of Transportation licensing office. Once you pay the appropriate fees you will be issued a title or registration and license plate to be attached to the trailer.
U.S.A. RESIDENTS TO CONTACT NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION
If you believe that your vehicle has a defect, which could cause an accident, personal injury or death, immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Marlon Recreational
Products Ltd.
If NHTSA receives similar complaints, or finds safety defects existing in a group of vehicles it may open an investigation or order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your dealer, or Marlon Recreational Products Ltd.
To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1 800-424-9393 (or 366-0123 in Washington, DC area) or write to: NHTSA, U.S. Department of Transportation, Washington, DC 20590.
FAQ
- Q: What parts are not covered by the warranty?
A: The warranty excludes expendable parts such as blades, hardware, tires, bearings, and other consumables listed in the manual. - Q: How can I contact NHTSA for vehicle defects?
A: You can call the Auto Safety Hotline toll-free at 1 800-424-9393 or write to NHTSA, U.S. Department of Transportation, Washington, DC 20590.
Documents / Resources
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DK2 MMT5X7 Series 5 X 7 ft Utility Trailers [pdf] User Manual MMT5X7, MMT5X7-DUG, MMT5X7G, MMT5X7G-DUG, MMT5X7 Series 5 X 7 ft Utility Trailers, MMT5X7 Series, 5 X 7 ft Utility Trailers, Utility Trailers, Trailers |