NB-1 Assembly Notes

Battery Holders (2 Required)

  1. Weld coupler pocket to Battery Box rail and Frame
     End rail. Be sure everything is square and that
     mounting holes are correct distance apart. You can
     bolt these rails to the side rails during welding
     to insure proper dimension.

Truck Assembly (2 Required)

  1. Bolt truck frames to transom spreaders with eight
     1/4"-20 x 1.25" bolts, lockwashers, and nuts.
  
  2. Bolt truck hangers to transom spreaders with two
     1/4"-20 x 1.5" bolts, lockwashers, and a pair of nuts.
     Grade 8 bolts with at least 3/4" unthreaded are
     recommended. Do not tighten bolt. Do tighten nuts.

  3. Bolt bearing blocks to truck frames with four
     1/4"-20 x 1/2" bolts, lockwashers, and nuts.

  4. For 7.25" gauge, use 3/4" ID x 1/8" thick washers
     between wheels and bearings. For smaller gauges,
     use a shaft collar at each end of axle.

  5. Pin wheels and sprockets to axle using
     1/4"-20 x 3/4" stainless steel setscrews threaded
     into both wheel/sprocket and axle.

Drive Assembly

  1. Pin sprockets to shafts using #10-32 x 1/2" stainless
     steel setscrews. Insure proper location and orientation
     of these components.

  2. The Output Shaft will require spacers at each end between
     sprockets and bearings. The Input Shaft will require same
     at one end and a collar at the other.

  3. Bolt four bearing blocks to the two Idler Mounting rails
     using eight 1/4"-20 x 1/2" bolts, lockwashers, and nuts.
     Slide assembled shafts into bearings. Make sure bearing
     and shaft orientations match drawings.

  4. Bolts the two Motor Mount rails inverted beneath the two
     Drive Mounting rails using 1/4"-20 x 1/2" bolts,
     lockwashers, and nuts.
     
  5. Bolt the two assembled Idler Mounting rails inverted
     beneath the two Drive Mounting rails using 1/4"-20 x 1.25"
     bolts, 1/2" spacers (between rails), lockwashers, and nuts.

  6. Insure assembly is square.

  7. Bolt Motor to Motor Mount rails. Hardware needed will
     depend on motor used.

  8. Install drive chains.

Frame Assembly

  1. During assembly, make sure everything is as square
     as possible. Battery Holders and Drive Assembly
     bolt on top of Frame rails. Equalizer Pivots mount
     inverted, below the Side Rails.

  2. Bolt two Battery Holders to Side Rails using four
     1/4"-20 x 1/2" bolts, lockwashers, and nuts for
     Frame End holes, and four 1/4"-20 x 3/4" bolts,
     lockwashers, and nuts for Battery Box holes. The
     extra length will be needed later for pilot braces.
  
  3. Bolt Drive Assembly to Side Rails using four
     1/4"-20 x 1/2" bolts, lockwashers, and nuts.

  4. Bolt two Equalizer Pivots to Side Rails using four
     1/4"-20 x 1/2" bolts, lockwashers, and nuts.
  
  5. Bolt four Pilot Brackets to End Rails using eight
     1/4"-20 x 1/2" bolts, lockwashers, and nuts.

Final Assembly

  1. Bolt Trucks to Frame Assembly using eight
     1/4"-20 x 3/4" bolts, lockwashers, and nuts.

  2. Bolt two Equalizer Beams to Equalizer Pivots using
     1/4"-20 x 1" bolts, flat washer, and pair of nuts.
     Do not tighten bolt. Do tighten nuts. Grade 8 bolts
     with at least 3/8" unthreaded are recommended.

  3. Insert four 1/4"-20 x 1.5" bolts and nylon-insert 
     stop nuts at the ends of the equalizer beams. Bolts
     at the top, nuts underneath. Adjust nuts so that all
     four bolts contact the truck frames and project at
     equal distances. Do not tighten.

  4. Attach four pilot braces (thinwall tubing) to the
     four 3/4" long frame bolts.

  5. Mount two Pilots using eight 1/4-20 x 1/2" bolts,
     lockwasher, and nuts.

  6. Bolt couplers into pockets using 1/4"-20 x 1.5" bolts
     with at least 1" unthreaded and nylon-insert stop nuts.

  7. Install drive chains.