ALL-TERRAIN
WAGON
ASSEMBLY INSTRUCTIONS
Mfg No.: TC1801T
WARNING CAUTION
NOT FOR CHILDREN UNDER 18 MONTHS OF AGE
Adult supervision is always required while this wagon is being Adult assembly required.
used by children. An adult should inspect the wagon periodically
to check for loose fasteners or damaged
components and fix or replace the part(s).
WARNING Make sure all exposed screw ends are capped to
prevent possible injury.
Do not over inflate pneumatic tires. Follow the tire At the assembly process, make sure all cotter
pressure guidelines listed on the tire. pins (G) have been bent into a butterfly shape to
Do not use wagon if one or more tires is not prevent possible injury.
properly inflated. The maximum number of riders that this wagon
Do not use wagon near or on stairs, or leave wagon is designed to carry at one time is two (2) – not
unattended on steep slopes. to exceed the maximum load weight of 200 lbs.
Do not ride in wagon down slopes or up steep Always use in a safe manner. Avoid use in public
inclines. streets or in places of high traffic.
Do not stand up in wagon or ride wagon standing. Do not operate the wagon if any parts are missing
Be extremely careful when operating the wagon on or need to be replaced. Failure to follow this
rough terrain or turning sharply. warning could result in serious personal injury.
PARTS LIST
C,G,
E
H,I
D,K,
A,G,H,I G,H F
B,J
N Q R
P
O
L
S
M
U
T
Part # Description Qty Part # Description Qty
A 6mm diameter x 1.5cm long Phillips Head Bolt 8 L Wagon Tray 1
B 6mm diameter x 4.5cm long Phillips Head Bolt 10 M 10"x3.50-4 Pneumatic Tires/Inner Tube/Rim 4
C 6mm diameter x 5cm long Slotted Head Bolt 1 N Pull Handle 1
D 6mm x 3cm long Carriage Bolt 2 O Front Axle 1
E 16mm Flat Washer 4 P Front Axle Support 1
F Cotters Pins 5 Q Rear Axle 1
G 6mm Flat Washers 9 R Rear Axle Support 2
H 6mm Lock Washers 9 S Front Wood Panel 1
I 6mm Hex Nuts 7 T Rear Wood Panel 1
J 6mm Hex Cap Nuts 10 U Side Wood Panels 2
K 6mm Grooved Hex Nut 2
Tools Required (not included)
#2 Phillips Screwdriver Slotted Screwdriver 10mm Wrench Long-Nose Pliers Adjustable Wrench
ASSEMBLY PROCEDURE
Step 1
Locate the wagon tray (L), rear axle assembly (Q), rear axle supports (R) and mounting hardware
bolts (A), flat washer (G), lock washer (H) and hex nuts (I).
Step 2
Using bolts (A), flat washer (G), lock washer (H),
and hex nuts (I), attach rear axle assembly (Q)
to the wagon tray (L). Washers and nut should be
located on the bottom of the wagon.
Tighten nuts and bolts using #2 Phillips screwdriver
and 10mm wrench.
Step 3
Slide rear axle supports (R) onto the axles and
attach to wagon tray (L) using bolts (A), flat
washer (G), lock washer (H) and hex nuts (I).
Tighten nuts and bolts using #2 Phillips screwdriver
and 10mm wrench.
Step 4
Install Front Axle “O” vertically (see Fig.1) and secure it with Cotter Pins (F) making sure to bend both
ends of each pin so that you form a butterfly shape.
Fig.1
ASSEMBLY PROCEDURE (continued)
Step 5
Connect entire front axle assembly to the wagon
tray (L) using bolts (A), flat washer (G), lock washer
(H), and hex nuts (I) and bolts (D), flat washer (G),
lock washer (H), and grooved hex nuts (K).
Tighten bolts with #2 Philips screwdriver and 10mm
wrench.
Step 6
Attach tires (M) to rear axle assembly (Q) using
cotter pins (F) and large flat washers (E). First
slide tire onto the axle. Next, insert large flat
washer (E) and secure it with a cotter pin (F)
making sure to bend both ends of each pin to
protect against its sharp edges. Repeat this
process to attach the tires to the front axle
assembly.
Butterfly shape
Step 7
Attach pull handle (N) to front axle assembly using
slotted head bolt (C), flat washer (G), lock washer
(H), and hex nut (I). Tighten nut and bolt using flat
screwdriver and 10mm wrench.
Step 8
Attach wood panels (S,T,U) to the front, rear, and
sides of the wagon using bolts (B) and capped
hex nuts (J). The wood panels mount to the outside
of the wagon tray. (Note: The bolt should be inserted
from the inside of the wagon tray and through the
wood, and fixed in place using capped hex nuts on
the outside). Tighten nuts and bolts using #2 Phillips
screwdriver and 10mm wrench.
Caution: Be sure not to over tighten as this will
push the bolt through the cap leaving a sharp
point.
REV.070109.TC1801T