3Com 45-0240 User Manual
OWNERS
MANUAL
Model No.
45-0240
UTILITY CART
CAUTION:
Read Rules for
Safe Operation
and Instructions
Carefully
PRINTED IN USA
Assembly
Operation
Maintenance
Repair Parts
FORM NO. 46274
LOOSE PARTS IN CARTON
1
8
12
Carton Contents
1. Tool Holder Brackets (2)
2. Tailgate Guides (2)
3. Corner Caps (2)
4. Latch Lock Sub-Assembly
5. Hitch Bracket
6. Latch Stand Bracket
7. Tailgate Reinforcement Bracket
2
3
4
6
5
10
9
13
8. Tailgate
9. Front Panel
10. Wheel Support
11. Axle
12. Draw Bar Tongue
13. Cart Body (2)
14. Wheels (2)
7
11
14
Ref. Qty. Description
A 2 Hub Cap
B 2 Cotter Pin, 1/8" Dia. x 1-1/2"
C 4 Washer, Flat 1.032" ID
D 27 Hex Bolt, 1/4" x 1/2"
E 6 Hex Bolt, 1/4" x 5/8"
F 6 Hex Bolt, 1/4" x 3/4"
G 2 Hex Bolt, 1/4" x 1-3/4"
H 41 Lock washer, 1/4" ID
I 41 Hex Nut, 1/4" Thread
J 14 Slotted Truss Hd Bolt, 5/16" x 3/4" Lg.
K 14 Lock Washer 5/16" ID
L 14 Hex Nut 5/16" Thread
M 2 Hex Bolt, 3/8" x 1"
N 2 Lock Washer, 3/8" ID
O 2 Hex nut, 3/8" Thread
P 1 Hitch Pin
Q 1 Hairpin Cotter
R 2 Spacer Tube, 2" Lg.
S 2 Protective Edging Strip
A
E
I
L
P
FIGURE 1 - HARDWARE PACK
2
B
M
C
F
G
J
N
Q
S
D
H
K
O
R
ASSEMBLY INSTRUCTIONS
1/4" x 3/4"
HEX BOLT
1/4" LOCK
WASHER
5/16" X 3/4"
SLOTTED BOLT
5/16" LOCK
WASHER
5/16" HEX
NUT
1/4"
HEX
NUT
TAILGATE
REINFORCEMENT
BRACKET
TAILGATE GUIDE
TOOLS REQUIRED FOR ASSEMBLY
(1) Screwdriver
(1) Pliers
(2) 7/16" Wrenches
(2) 1/2" Wrenches
(2) 9/16" Wrenches
(1) Power Drill (See paragraph 19, Pg. 6)
1. Remove the hardware pack and all loose parts
from the carton. Be sure the carton is empty
before discarding.
2. Lay out all the parts as shown in the carton contents.
CAUTION
To help prevent tipping of cart, assemble on a
smooth level surface such as a garage floor or a
paved driveway. Pay close attention to stability of the
cart body when it is in an upright position. DO NOT
LEAVE THE CART UNATTENDED IN UPRIGHT
POSITION. The cart could be knocked over causing
personal injury or damage to the cart.
5. Position the tailgate reinforcement bracket on
outside of cart as shown in figure 3. Assemble to
holes in bottom of cart body using six 5/16" slotted
head screws, 5/16"lock washers and 5/16" hex
nuts. Do not tighten. See figure 3.
6. Position the tailgate guides (with mounting holes
to the rear) on the inside of the cart bodies as
shown in figure 3. Assemble using six 1/4" x 3/4"
hex bolts, 1/4" lock washers and 1/4" hex nuts as
shown in figure 3. Do not tighten.
FIGURE 3
3. Position cart body halves upright on a smooth
level surface as shown in figure 2.
4. Assemble halves together using seven 1/4" x 1/2"
hex bolts, 1/4" lock washers and 1/4" hex nuts. Do
not tighten at this time. See figure 2.
.
1/4" x 1/2"
HEX BOLT
1/4" HEX
NUT
1/4" LOCK
WASHER
7. At this time tighten the six slotted head screws in
the bottom of cart. Next, tighten the six hex bolts
fastening the tailgate guides. Finally, underneath
the cart, tighten the seven hex bolts fastening the
cart bodies together.
8. Carefully reverse the position of the cart so that it
rests on its opposite end, on the tailgate reinforcement bracket, as shown in figure 4. Proceed with
the following assembly steps.
FIGURE 2
FIGURE 4
3
9. Assemble the front panel over the open end of the
cart using ten 1/4"x1/2" hex bolts, 1/4" lock washers and 1/4' hex nuts. Insert bolts down through
the two middle holes and the two outside holes in
the bottom of cart body, and through the top,
bottom and middle holes on each side of the cart
body. Check that the cart halves are butted together and tighten the bolts through the bottom of
the cart first; then tighten the bolts through the
sides of the cart. See figure 5.
11. Assemble latch stand bracket using four 1/4" x
5/8" hex bolts, 1/4" lock washers and 1/4" hex
nuts. See figure 7. TIGHTEN.
LATCH STAND BRACKET
1/4" x 5/8"
HEX BOLT
LEAVE HOLES OPEN FOR
LATCH STAND BRACKET
1/4" x 1/2"
HEX BOLTS
1/4" HEX NUT
1/4" LOCK
WASHER
1/4" HEX NUT
FIGURE 5
10. Assemble the wheel support to the cart using
eight 5/16" x 3/4" slotted head screws, 5/16" lock
washers and 5/16" hex nuts as shown in figure 6.
Heads of screws go to the inside of cart. Tighten.
1/4" HEX NUT
1/4" LOCK
WASHER
FIGURE 7
12. Assemble two front top corner caps using four
1/4" x 1/2" hex bolts, 1/4" lock washers and 1/4"
hex nuts. Also assemble two 1/4" x 1/2" hex bolts,
1/4" lock washers and 1/4" hex nuts through top
flanges and tailgate reinforcement bracket at the
two rear corners. See figure 8. TIGHTEN.
WHEEL
SUPPORT
5/16" HEX
NUT
FIGURE 6
5/16" LOCK
WASHER
SLOTTED SCREW
5/16" x 3/4"
4
CORNER CAP
1/4" x 1/2"
HEX BOLT
FIGURE 8
1/4" LOCK
NUT
1/4" LOCK
WASHER
1/4" LOCK
NUT
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