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

13. Lower the cart assembly to rest upside down on its

COTTER PIN

SPACER TUBE

WHEEL

HUB CAP

1" FLAT
WASHER

1" FLAT
WASHER

AXLE

top flanges, with wheel support up. See figure 11.

14. Assemble latch lock subassembly to drawbar
tongue using two 1/4" x 5/8" long hex bolts, lock
washers and hex nuts. Tighten. See figure 9.

1/4" x 5/8"

LATCH LOCK
SUB-ASSEMBLY

DRAW BAR
TONGUE

HEX BOLT

1/4" x 1-3/4"
HEX BOLT

1/4" LOCK
WASHER

1/4" HEX NUT

FIGURE 11

AXLE

DRAW BAR
TONGUE

WHEEL
SUPPORT

1/4" LOCK
WASHER

1/4" HEX NUT

FIGURE 9

15. Assemble hitch bracket to drawbar tongue, using
two 3/8" x 1" hex bolts, 3/8" lock washers and 3/8"
hex nuts. See figure 10.

3/8" x 1"

TONGUE

HEX BOLT

17. Assemble a spacer tube, a 1" flat washer, a wheel
with the valve stem facing out, and another 1" flat
washer onto the axle as shown in figure 12. Se­cure with a cotter pin and spread ends so that hub
cap can fit over the cotter pin . Assemble the hub
cap by pressing it onto the flat washer. Repeat for
other end of axle.

FIGURE 12

3/8" LOCK
WASHER

FIGURE 10

16. Assemble axle and drawbar tongue to wheel sup­port keeping the open side of tongue facing away
from cart. Make sure the latch lock snaps over the
top of latch stand bracket. Secure axle to wheel
support using two 1/4" x 1-3/4" hex bolts, lock
washers and hex nuts. See figure 11.

3/8" HEX
NUT

18. Turn cart over so that it rests right side up on its
wheels.

5

19. To mount the tool holder brackets to the front of
the cart it will be necessary to drill four holes in the
front panel of the cart. (Recommended hole size is
9/32" diameter.) The tool bracket holders may be
used to locate hole positions by placing the bracket
against the front panel and marking the hole loca­tions onto the front panel. The top tool holder
bracket should be positioned equally from each
side of the cart and even with the top edge of the
front panel. The bottom tool holder bracket should
be positioned equally from each side of the cart
with the top of the bracket approximately six inches
up from the bottom. See figure 13.

20. Press the protective edging strips over the top
edge of both tool holder brackets. Mount the tool
holder brackets on the inside of the front panel of
the cart using four 1/4" x 1/2" hex bolts, 1/4" lock
washers and 1/4" hex nuts. See figure 13.

1/4" HEX NUT

FIGURE 13

21. Place the tailgate down into the tailgate guides so
that the holes in bottom lip of tailgate fit over
heads of slotted head screws in bottom of cart.
This completes the assembly of your cart.

1/4" LOCK
WASHER

TOOL HOLDER
BRACKET

1/4" x 1/2"
HEX BOLT

6

GENERAL SAFETY PRECAUTIONS

MAINTENANCE:

Preventing accidents is the responsibility of every
equipment operator. The following general safety
precautions must be fully understood and followed by
every operator.

1. Do not at any time carry passengers in this cart.
It is designed for carrying materials only and not
intended to carry passengers.

2. Do not tow this utility cart on a public throughfare
at any time. The operator is risking injuries from
passing vehicles. Most local ordinances prohibit
operating a cart and tractor such as this on a
public throughfare.

3. When towing cart do not drive to close to a creek
or ditch and be alert for holes and other hazards.
The above could cause you to loose control of the
cart and tractor.

4. Be careful on any grade (hill) and stay off of steep
grades.

5. Maximum towing speed - 10 M.P. H.

OPERATION

To dump material from the cart, remove the tailgate by
lifting it straight up and out from between the guides.
Release the spring latch by pulling the latch handle
forward, away from the cart. The cart bed will tilt
backwards to empty its contents. After unloading, pull
the front of the bed down toward the cart tongue until
the latch snaps in place. Replace the tailgate if de­sired.

At the beginning of each season, lubricate the latch,
latch pivot bolt, and the axle where the draw bar
tongue pivots, with a light machine oil.

1. Grease or oil wheel bearings occasionally. Use
automotive wheel bearing type grease or 20 weight
oil.

2. Keep tires filled to recommended tire pressure of
12-14 Lbs.

NOTE

One cubic foot of dirt weighs approximately 150 lbs.

DO NOT EXCEED WEIGHT CAPACITY OF 1000 LBS.

Bed: 18 Ga. Steel Construction-32-1/2" W; 49"L;

12"H; Approx. Inside Dim.-30" x 46-1/2"

Tailgate: Removable with reinforced guides
Tires: 15.00" x 6.0" Pneumatic, Turf Tread
Axle: 1.0" Dia. Steel
Capacity: Up to 1000 Lbs.
Finish: Powder Coated
Approx. Sh. Wt.:
Carton Size: 18"H x 21"W x 49"L (10.72 Cu.Ft.)

116Lbs.

To avoid possible injury, be sure that
no one is near the trailer before re­leasing the latch.

NOTE

For best handling, do not load cart too
heavily behind center of axle.

7

REPAIR PARTS FOR: UTILITY CART MODEL NO. 45-0240

4

24

25

16

20

18

3

1

8

15

22

5

27

28
29

20

25

24

24

27

28
29

25

1

24

25

14

20

21

A

21

24

2

6

25

A

24

25

9

20

14

7

24

25

20

24

25

17

19

18

13

13

23

8

12

24

25

10

31

32

30

26

11

33

REPAIR PARTS LIST FOR UTILITY CART MODEL NO. 45-0240

REF. PART QTY. DESCRIPTION
NO. NO.

1 23985 2 Cart Body
2 46138 2 Protective Edging Strip
3 23502 1 Tailgate
4 62458 1 Tailgate Reinforcement Bracket
5 23767 2 Guide, Tailgate - One Piece
6 23918 2 Tool Holder Bracket
7 23492 1 Front Panel
8 23507 1 Wheel Support
9 23297 1 Latch Stand Bracket
10 62455 1 Ass'y, Latch Lock
11 23014 1 Hitch Bracket
12 23988 1 Draw Bar Tongue
13 23488 1 Wheel Axle 1" Dia.
14 23484 2 Cap, Front Corner
15 44678 2 Sleeve Tube (Spacer)
16 46272 2 Wheel, 15.00 x 6.00
17 43093 2 Cotter Pin, 1/8" Dia. x 1-1/2"
18 43601 4 Washer, Flat 1.032" ID
19 43014 2 Hub Cap
20 43175 27 Hex Bolt, 1/4" x 1/2"
21 43866 6 Hex Bolt, 1/4" x 5/8"
22 43012 6 Hex Bolt, 1/4" x 3/4"
23 1509-69 2 Hex Bolt, 1/4" x 1-3/4"
24 43177 41 Lock washer, 1/4" ID
25 43178 41 Hex Nut, 1/4" Thread
26 23353 1 Hitch Pin
27 43814 14 Slotted Truss Hd Bolt 5/16" x 3/4" Lg.
28 43086 14 Lock Washer 5/16" ID
29 43083 14 Hex Nut 5/16" Thread
30 43001 2 Hex Bolt, 3/8" x 1"
31 43003 2 Lock Washer, 3/8" ID
32 43015 2 Hex nut, 3/8" Thread
33 43343 1 Hairpin Cotter

46274 1 Owner's Manual

* Purchase Common Hardware Locally

9

10

11

REPAIR PARTS

303 West Raymond

Sullivan, IL. 61951

217-728-8388