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What to expect
In this activity, we will build the rolling cart for the dual-axis solar tracker with a portable power pack.
Materials - Note: You will not need to assemble the side pieces of the body.
Instructions
Familiarize yourself and unpack all of the cart parts. Use the adjustable wrench to fasten the nuts and bolts. Hint: Do not fully tighten nuts and bolts until you have most of the cart put together. Additional hints about this are given throughout this document.
1. Find the back axle and place it over the square holes at one end of the main frame of the cart.
A. Make sure that the raised back at the base is facing away from the center of the cart.
B. On either side, thread a small bolt through the top of the cart through the square hole.
C. Then, on the bottom, put a washer on the bolt and secure it with a small nut.
2. Take both axle braces and slide them onto each end of the back axle. The flat end of the brace should be on the outside.
3. Place the other end of each axle brace directly over the holes on the bottom of the cart’s main body.
A. Secure each brace by putting a small bolt through the bottom of the square part of the hole.
B. Place a washer on top of the bolt and secure it with a small nut.
4. Move to the other end of the main cart body. Grab the front axle, the yoke piece, and a large bolt.
A. Place the axle flat with the raised back at the base facing up.
B. Place the hollow pipe part of the yoke piece in between the top and bottom of the front axle.
C. Slide the long bolt through the bottom of the front axle and the hollow pipe part of the yoke piece.
5. Take the single front axle brace and
A. Place it onto the top of the long bolt. The axle brace should be directly on the other side of the front axle compared to the end of the yolk.
B. Secure the brace to the axle by placing a washer and a small nut on the end of the long bolt.
6. Locate the steering connector.
A. Attach it by lining up the moving pieces of the axle with the yoke as pictured.
B. Place the center hole of the steering connector onto the pole, sticking it vertically out from the yolk. The moving pieces of the front axle should sit under the steering connector.
C. Thread a small hex bolt through the bottom of each side of the steering connector.
D. Place a washer on top of the bolts and secure them with a small nut. MAKE SURE NOT TO TIGHTEN THEM FULLY, OR THE CART WILL NOT BE ABLE TO STEER.
E. Put the small (cotter) pin through the hole in the pole, sticking it vertically out of the yolk.
7. Push the pin through as far as possible. Slightly separate the ends of the pin so it gets stuck in the pole, sticking out vertically from the yolk.
8. Place the constructed front axle onto the front of the bottom of the main body of the cart make sure that the yolk is faced out.
A. While the front axle brace is facing inward over the hole in the center of the cart's main body.
B. Connect the front axle to the main cart body by placing a small bolt through the bottom square hole.
C. Then, place a washer and small nut on top.
9. Connect the front axle brace to the main cart body by using the same process at the back axle.
A. Put the back axle brace directly over the holes on the bottom of the cart’s main body.
B. Secure each brace by putting a small bolt through the bottom of the square part of the hole.
C. Place a washer on top of the bolt and secure it with a small nut.
10. Place the four wheels on the four ends of the front and back axles.
Attach the wheels to the cart with the 4 large nuts, placing the 4 large washers on beforehand. DO NOT SCREW THEM TOO TIGHT OR THE CART WILL NOT ROLL.
12. Attach the handle.
A. Place the end of the handle onto the end of the yolk sticking out from the front end of the cart.
B. Slide the long hex bolt through the holes of the handle and the holes on the yolk.
C. Secure the bolt by placing a washer and a small nut on the end of the bolt. DO NOT SCREW ON FULLY, OR YOU WILL NOT BE ABLE TO MOVE THE HANDLE.
Final Step:
Test the cart to make sure it rolls ok! Gently snug, but do not overtighten bolts.
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