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rad3 Base Box User manual

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Page 1 from
24
Instructions rad3_bullitt_kids_box_2022 09
12
rad3 BULLITT Base Box / Kids Box / Tarpaulin / Canopy
Congratulations on your
purchase decision and have
fun on your venture!
Enclosed are some instructions
for the use, assembly and care
of the box.
We have tried to keep the total weight as low as possible during the construction. Nevertheless,
you should work in pairs if necessary during assembly and observe the usual rules for handling
heavy and bulky objects - for the sake of your health.
The box is adapted for the Bullitt type cargo bikes and tested with the 2013 and 2015 frames - also
with STePS drive, in today's version 2 also for the larger tolerances especially with the E8000. The
Canopy does NOT fit on the E8000, as a wider handlebar is installed here (shortening possible at
your own responsibility).
At the front, at the bottom and at the back, the panels are attached to the existing mounting
brackets on the frame.
NOTE: Unfortunately, the tolerance of the frames is sometimes VERY large, you may have to
widen our holes. We ask for your understanding.
The box itself is a kit made of 5 panels:
1x front, 1x base, 1x back, 2x sides and in the standard version 1x backrest with foam.
rad3 accepts no liability for faults and consequential faults resulting from assembly and use
deviating from the intended area of use. This also applies to own attachments and modifications
to the box.
We create step by step video tutorials - please have a look at https://vimeo.com/rad3de/
You will need some manual dexterity and the following tools for assembly:
Allen key 4 / 5 / 6 mm Open-
ended / ring spanner 10 mm
for tarpaulin and canopy
(Rechargeable) drill 1.5
mm drill bit
Cross-recess screwdriver PZ2 Ruler
Pin / Scriber
Some of the photos still show pre-series types. Don't let this irritate you - the technology is the
same - we will update this.
Subscribe to DeepL Pro to translate larger documents.
Visit www.DeepL.com/pro for more information.
Page 2 from
24
Instructions rad3_bullitt_kids_box_2022 09
12
Revisions:
Designation
Changes (focal points)
Date
Instructions-
rad3_bullitt_kids_box_
2022-09-12.pdf
Small corrections: 8 instead of 10 push buttons for
tarpaulin, 3 additional washers for front panel, additions
for 5-point harnesses, note on creaking
12.09.2022
Instructions-
rad3_bullitt_kids_box_
2019-11-10.pdf
Kidsbox version 10.2, elongated holes in the front panel to
compensate for tolerances (especially E8000), holes in the
rear wall enlarged t o compensate for tolerances, belt
guide optimised, foam backrest no longer glued but velcro
instead, small geometric optimisations, (preparation for)
side with door as option, modified canopy
10.11.2019
Instructions-
rad3_bullitt_kids_box_
2019-05-31.pdf
31.05.2019
Instructions-
rad3_bullitt_kids_box_
2019-03-15.pdf
15.03.2019
Instructions-
rad3_bullitt_kids_box_
2019-01-19.pdf
19.01.2019
Instructions-
rad3_bullitt_kids_box_
2018-03-15.pdf
15.03.2018
Instructions-
rad3_bullitt_kids_box_
2017-12-01.pdf
01.12.2017
Instructions-
rad3_bullitt_kids_box_
2017-07-21.pdf
21.07.2017
Instructions-
rad3_bullitt_kids_box_
2017-04-22.pdf
First edition
22.04.2017
Page 3 from
24
Instructions rad3_bullitt_kids_box_2022 09
12
0. the accessories - please check for completeness before
assembly
Base Box:
3 pcs. Flange head screws M6 x 60 mm (front panel)
4 pcs. countersunk head screws M6 x 70 mm (base
plate) 4 pcs. Flange head screws M6 x 25 mm (back
plate) 14 pcs. K-washers M6
4 pcs. locking cap nuts M6 7 pcs.
locking nuts M6
7 pcs. Plastic sleeves 20 mm (base plate + front plate)
4
pcs. Plastic sleeves 15 mm (base plate)
1 pc. tensioning
strap if necessary
protective inserts
Fig. 0-1:
the accessories Basis Box /
Kids Box
kids accessories:
2 pcs. Y-Gute Standard or Fidlock (bottom 40 mm webbing)
4-8 pcs. Belt buckles for 25 mm belt width (for standard belts)
2 pcs. Belt buckles for 40 mm belt width (for Fidlock belts and standard at the bottom for wide
slots!)
Tarpaulin:
8 press studs
8 pan-head screws 3.9 x 6.5 mm
Canopy
10 press studs
8 pan-head screws 3.9 x 9.5 mm for columns (9mm)
2 pan head screws 3.9 x 6.5 mm for sides (6mm panels) 2 rod
sleeves with
4 pcs. Flange head screws M6 x 20 4
pcs. lock nuts M6
4 pcs. K-washers M6
4 pcs. K-washers M6 small
Page 4 from
24
Instructions rad3_bullitt_kids_box_2022 09
12
Fig. 0-2:
the accessories for
kids comparison
straps above: Fidlock
Below: Standard
Fig. 0-3:
The Canopy accessories
Fig. 0-4:
the accessories tarpaulin
screws 3.9 x 6.5mm
Page 5 from
24
Instructions rad3_bullitt_kids_box_2022 09
12
1.
To protect your bike and reduce noise, you should enclose e.g. strips of an old bicycle inner
tube between the panels and the frame. Of course, you can also use professional (thick) paint
protection film or insulation foam strips.
If you buy your Bullitt from us, we can use partition tape B1 from Würth ®.
Fig. 1-1:
Protective supplement
Paint protection,
noise
reduction
Fig. 1-2:
with Würth tape
(glued on the
underside!)
2.
If necessary, fit the belts as described in point 9 now - it is easier.
Place the bottom panel from front to back on the base frame, taking care if necessary t h a t
the inserts do not slip. Align the plate so that the distances to the frame are even on the right and
left.
Fig. 2:
Insert base plate, screw
points
Page 6 from
24
Instructions rad3_bullitt_kids_box_2022 09
12
3.
Insert 4 countersunk screws 75 mm at the holes marked above. On the underside, the
sleeves 20+15 mm must be inserted.
Place a K washer (round edge to the frame / paint) and a nut on each from below and
screw
them on loosely.
Fig. 3:
Screws 70 mm
Sleeve sets 20+15
mm K-washers Lock
nuts
4.
Place the back panel in the centre. Insert 4 flange head screws 25 mm at the
designated holes.
Fig. 4-1:
Put on rear wall, screws 25
mm
K-washers Cap nuts
Fig. 4-2:
View from the driver Disc
with cap nuts
Page 7 from
24
Instructions rad3_bullitt_kids_box_2022 09
12
Place a K washer (round edge to the frame / paint) and a cap nut / nut on each from the rear and
screw them on loosely.
5.
Place the front panel in the centre. Insert 3 flange head screws 60 mm at the
designated slotted holes. New: please also use additional
washers
on the inside.
Fig. 5
Put on front panel, screws 60
mm
K-washers
Locknuts
6.
On the front side, the sleeves must be inserted 20 mm.
Place a K washer (round edge to the frame / paint) and a nut on each from the front and screw
them on loosely.
ATTENTION, here it is particularly important not to tighten the nuts yet, as the panel must be
aligned in height AFTER inserting the sides. There is usually a gap of 2-5 mm between the
bottom and the base plate.
Fig. 6
Put on front panel, screws 60
mm
K-washers
Locknuts
Page 8 from
24
Instructions rad3_bullitt_kids_box_2022 09
12
7.
Once again, align all the panels centrally to the frame and to each other and then carefully
tighten the nuts one after the other but not quite yet. It should still be possible to move the front
panel in particular.
Fig. 7:
Align panels, tighten nuts
loosely
After complete bolting, you can also transport bulky objects crosswise on your bike without any
problems with the structure now shown here.
For the expansion to a box, continue to assemble as follows (note the points from 10 for the kids
box!).
8.
Insert the side panels and align them in the longitudinal axis so that you have an even
projection at the front panel and rear.
Fig. 8:
Insert side parts, tighten
nuts with torque
Now tighten all the screws.
ATTENTION, the torque should be 4-8 Nm.
If the torque is too low, the stability of the box is at risk!
If the torque is too high, the plate may warp, the sleeve may be damaged or the screw may pull
through the plate!
Page 9 from
24
Instructions rad3_bullitt_kids_box_2022 09
12
9.
The straps in the backrest and the base plate
If you would like to use your box for transporting children and have ordered the seat backrest as
well, you must thread the straps into the corresponding openings and insert the buckles to
secure them before inserting the box as described in point 10.
You can use one strap in the middle for one child or 2 straps on the right and left for 2 children.
The shoulder straps can be fastened in 3 heights depending on the size of the child.
If possible, pull the belt through the opening first.
Please then thread the buckle as follows. This is the only way to ensure that the belt cannot slip.
The belt only goes through ONE slot, the buckle has to work as a barb.
Fig. 9-1:
Strap guide in the buckle
25mm standard strap
Fig. 9-2:
Belt guide on the box
Page 10 from
24
Instructions rad3_bullitt_kids_box_2022 09
12
Fig. 9-3:
Belt guide below for
-
25mm standard belts
-
40mm Fidlock harnesses
Fig. 9-4:
IMPORTANT for safety!
Bottom belt guide for
25mm standard belts
for a base plate with
40mm
slots