Harbor Freight Tools 91240 Assembly And Operating Instructions Manual

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ASSEMBLY AND OPERATING INSTRUCTIONS

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91240

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3491 Mission Oaks Blvd., Camarillo, CA 93011

Visit our W eb site at http://www.harborfreight.com

Copyright © 2004 by Harbor Freight Tools®. All rights reserved. No por tion of this
manual or any artwork contained herein may be reproduced in any shape or form
without the express written consent of Harbor Freight Tools.

For technical questions and replacement parts, please call 1-800-444-3353

Specifications

This rugged wagon is durable, useful and fun! The PVC body and zinc plated and
painted metal parts are rust and weather resistant. The heavy duty pneumatic tires
offer strength and a smooth ride. The attractive wooden sides will keep kids and
loads in the wagon, where they belong.

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Contents

Upon opening, check the package to be sure that no parts are missing, and none
are damaged. In case of missing or damaged parts, please call the number on the
front of this manual.

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Save This Manual

You will need the manual for the saf ety warnings and precautions, assembly
instructions, operating and maintenance procedures, parts list and diagram. Keep
your invoice with this manual. Write the invoice number on the inside of the front
cover . Keep the man ual and invoice in a saf e and dry place for future reference.

SKU 91240 Page 2

Safety Warnings and Precautions

WARNING: When using this product, basic safety precautions should alwa ys
be followed to reduce the risk of personal injury and damage to equipment.

Read all instructions before using this tool!

1. Keep work area clean. Cluttered areas invite injuries.

2. Observe work area conditions. Keep work area well lighted.

3. Keep children away. Children m ust never be allo wed in the work area. Do
not let them handle machines or tools. Do not let unsupervised children play
with this product. Serious injury could result.

4. Store idle equipment. When not in use , equipment must be stored in a dry
location to inhibit rust. Always lock up equipment and keep out of reach of
children.

5. Use the right tool for the job. Do not attempt to f orce a small item to do the
work of a larger industrial item. Do not modify this item and do not use this
item for a purpose for which it was not intended. Do not exceed the 300 lbs.
maximum weight capacity. Note: The wooden sides provide limited support
to keep objects in the wagon; wooden sides are not designed to provide
significant weight support.

6. Do not overreach. Keep proper f ooting and balance at all times. Do not
stand on this wagon. When unattended, be sure it will not accidently roll
awa y. Use the wagon sensib ly; be careful not to ov erload or tip the wagon
over.

7. Maintain tools with care. Follow instructions for lubricating and changing
accessories. The handles m ust be kept clean, dry, and free from oil and
grease at all times.

8. Stay alert. W atch what you are doing, use common sense. Do not oper ate
any item when you are tired.

9. Do not wear loose clothing. Do not allow loose clothing, hair or hands to
get caught in the moving parts of this wagon.

10. Check for damaged parts. Before using any item, an y part that appears
damaged should be carefully checked to determine that it will operate
properly and perform its intended function. Check for alignment and binding
of moving parts; any broken parts or mounting fixtures; and any other
condition that may affect proper operation. Any part that is damaged should
be properly repaired or replaced by a qualified technician.

11. Replacement parts and accessories. When servicing, use only identical
replacement parts.

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13. Do not operate item if under the influence of alcohol or drugs. Read
warning labels on prescriptions to determine if your judgment or reflexes are
impaired while taking drugs. If there is any doubt, do not operate the item.

14. Maintenance. F or your saf ety , service and maintenance should be performed
regularly by a qualified technician.

15. Maintain 30 PSI tire air pressure for optimal rolling of wagon.

Warning: The warnings, cautions, and instructions discussed in this instruction
manual cannot cover all possible conditions and situations that may occur. It
must be understood by the operator that common sense and caution are fac­tors which cannot be built into this product, but must be supplied by the opera­tor.

Assembly

You will need 2 small wrenches and a pliers to complete assembly of this item.
(T ools are not included.) These tools may be obtained from Harbor F reight Tools.

WARNING: Be careful not to pinch your finger s as you proceed with assembl y .

Please refer to the Assembly Diagram on page 7 for part numbers.

First assemble the front and rear axle supports onto the wagon tra y.

1. Determine the front and rear orientation of the Tray (1). The front will have a
“triangle” bolt hole pattern of 3 holes to fit the Front Axle Support (8), and
Center Front Axle Brace (9). The rear will have a “square” bolt hole pattern of 6
holes to fit the Rear Axle Support (5) and Rear Axle Braces (6) and (7).

2. Find the Rear Axle Support (5), and place it in position on the rear underside
of the Tray (1). Insert a Hex Head Bolt (16) through one of the rearmost holes
in the Tray (1), and through the aligning hole in the Rear Axle Support (5).
Place a Lock Washer and Nut (16) on the bolt, and finger-tighten. Install the
second Bolt, Lock Washer and Nut (16) the same way.

3. Identify the Left and Right Rear
Axle Braces (6 and 7), by
comparing them to the photo.
Position these on the rear axle
with the flanges pointed in, to
align with the holes in the Tray
(1). Install Bolts, Lock Washers
and Nuts (16) as before. You ma y
now tighten all six bolts and nuts
for the Rear Axle Support (5). DO
NOT OVERTIGHTEN: Check to
be sure that the bolt heads do not
damage the plastic Tray (1) as
you tighten.

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4. Identify the Front Axle Support (8). Align it with the three predrilled holes on
the underside of the Tray (1). Install Bolts, Lock Washers and Nuts (16) as
before. You ma y now tighten all bolts and nuts f or the Front Axle Support (8).
DO NOT OVERTIGHTEN: Check to be sure that the bolt heads do not
damage the plastic Tray (1) as you tighten.

5. Attach each of the four Wheels (4) onto the axles. Slide each Wheel onto an
axle end, with the inflation valve of the wheel on the outside. Slide one of the
Washers (15) onto the end of the axle, and install an Acorn Nut (15). Tighten
the nut on each wheel in turn.

6. Install the Handle (13) by positioning
the Plastic Coupling (12) into the
end of the Yok e (10) as sho wn in
the photo. Insert the Handle
Fastener Bolt (18) through the Yoke
(10), and Plastic Coupling (12).
Place the Washer and Nylock Nut
from the Fastener Set (18) onto the
Handle Fastener Bolt, and secure.
NOTE: Do not overtighten the
Nylock Nut, the handle must still be
able to move up and down freely in
the Yoke.

7. With the wagon right side up, install
the wooden sides. First place the Side
Panels (2) and the Front and Rear Panels
(3) into the slots on the sides of the Tray
(1) as shown in the Assembly Drawing,
with the vertical slats on the outside.
Secure the corners of the sides together
using the Clips (14). WARNING: Be
careful not to pinch your fingers when
installing the clips. Slide them over the
corners of the sides as shown in the
photo.

SKU 91240 Page 5

8. Using a hand pump, inflate the tires to 30psi. WARNING: Do not use an air
compressor or other high-pressure source to inflate the tires, as they may
explode if over inflated.

Maintenance

1. Check the tire pressure periodically with a good quality air pressure gauge.
Maintain the tire air pressure at 30 psi. Inflate the tires using a hand pump to
avoid over inflation. Hand pump and pressure gauge are available at Harbor
Freight Tools.

2. Protect the wagon from excessive exposure to direct sunlight, rain, freezing
and other weather . Store the wagon in a dry , protected place when not in use .

3. Periodically check the bolts and other fasteners to be sure they are tight.

4. If the Wheels or Yoke squeak when in use, apply a heavy-duty lubricant. Do
not get oil-based lubricants on the plastic parts.

PLEASE READ THE FOLLOWING CAREFULLY

THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS DIAGRAM
IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER NOR
DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE
BUYER THAT HE OR SHE IS QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT OR
THAT HE OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT. IN FACT,
THE MANUFACTURER AND/OR DISTRIBUTOR EXPRESSLY STATES THat ALL REPAIRS
AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND LI­CENSED TECHNICIANS AND NOT BY THE BUYER. THE BUYER ASSUMES ALL RISK
AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT
OR REPLACEMENT PARTS THERETO, OR ARISING OUT OF HIS OR HER INSTALLA­TION OF REPLACEMENT PARTS THERETO.

NOTE: Some parts are listed and shown for illustration purposes only and are not
available individually as replacement parts.

SKU 91240 Page 6

Assembly Diagram

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SKU 91240 Page 7