ASSEMBLY
This unit is shipped WITHOUT GASOLINE or OIL. After assembly, see separate engine manual for proper fuel and engine oil recommendations.
TOOLS REQUIRED FOR ASSEMBLY
(1)Screwdriver
(1)Pliers
(2)7/16" Wrenches
(2)1/2" Wrench
(2)9/16" Wrenches
(2)3/4" Wrenches (only if figure 23 on page 12 is used)
REMOVAL OF PARTS FROM CARTONS
1.Remove the hardware packs and all loose parts from the cartons.
2.Lay out and identify parts shown in carton contents.
3.Lay out and identify parts in the hardware packs. Keep contents of each hardware package separate.
ASSEMBLING THE CART BODY
1.Place cart body halves upright on a smooth level surface such as a garage floor or a paved driveway. See figure 1.
CAUTION: Do not leave the cart unattended in upright position during assembly. A falling cart can cause personal injury! Pay close attention to the stability of the cart while it remains in an upright position. For best stability, assemble on a smooth level surface.
2.Assemble cart body halves together using three 1/4" x
5/8" hex bolts and 1/4" nylock nuts as shown in figure
1. Do not tighten yet.
1/4" x 5/8" HEX BOLT
1/4" NYLOCK NUT
3.Fit the tailgate reinforcement bracket over the end of the cart bed. Position the two door support brackets on the bottom of the reinforcement bracket as shown in figure 2. Fasten the reinforcement bracket and the door supports to the bottom of the cart using four 5/16" x 3/4" truss head bolts and 5/16" nylock nuts.
Do not tighten yet. See figure 2.
4.Fasten the tailgate reinforcement bracket to the sides of the cart body using four 1/4" x 5/8" hex bolts and
1/4" nylock nuts as shown in figure 2. Do not tighten yet.
1/4" NYLOCK NUT
1/4" x 5/8"
HEX BOLT
5/16" x 3/4" TRUSS HEAD BOLT
DOOR
SUPPORT 
| TAILGATE |
5/16" NYLOCK NUT | REINFORCEMENT |
BRACKET |
FIGURE 2
5.Pull the cart body halves together.
Tighten the four truss head bolts in figure 2. Tighten the four hex bolts in figure 2.
Tighten the three hex bolts in figure 1, keeping the bottom aligned and pulled together.
6.Carefully flip the cart end for end so that it rests on the tailgate reinforcement bracket. See figure 3.
FIGURE 1 | FIGURE 3 |
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