Owner’s Manual Powerwagon MODEL NUMBER: _________________________ SERIAL NUMBER: _________________________ DATE PURCHASED:________________________ Register your Generac product at: WWW.GENERAC.
WARNING CANCER AND REPRODUCTIVE HARM www.P65Warnings.ca.gov.
Table of Contents Section 1: Safety Rules & General Information Section 4: Maintenance and Troubleshooting Introduction ..................................................................1 Read This Manual Thoroughly ....................................1 Maintenance ...............................................................19 Safety Rules .................................................................1 How to Obtain Service .................................................1 Lubrication ..........
This page intentionally left blank.
Safety Rules & General Information Section 1: Safety Rules & General Information Introduction Thank you for purchasing this Generac Pro Powerwagon. This unit has been designed to provide high performance, efficient operation, and years of quality use when maintained properly. The Generac Pro Powerwagon is designed and built for consistent, reliable use for small digging projects. It is built to withstand frequent handling under these conditions.
Safety Rules & General Information General Hazards WARNING Accidental Start-up. Disconnect the negative battery cable, then the positive battery cable when working on unit. Failure to do so could result in death or serious injury. (000130) WARNING Personal injury. Keep people and pets away from work area. Failure to do so could result in death or serious injury. (000420) WARNING Personal injury. Only allow qualified persons to operate unit.
Safety Rules & General Information DANGER WARNING Personal injury. Do not ride or allow riders on the unit. Riding on and allowing riders could result in death, serious injury, or equipment damage. (000409) Explosion and Fire. Do not overfill fuel tank. Fill to 1/2 inch from top of tank to allow for fuel expansion. Overfilling may cause fuel to spill onto engine causing fire or explosion, which will result in death or serious injury. (000166b) DANGER WARNING Crushing hazard.
Safety Rules & General Information Fire Hazards WARNING Risk of Fire. Verify machine has properly cooled before installing cover and storing machine. Hot surfaces could result in fire. (000109) WARNING Risk of fire. Never operate engine without the air cleaner installed. Operating engine without the air cleaner could result in death or serious injury. (000249) WARNING Risk of Fire. Unit must be positioned in a manner that prevents combustible material accumulation underneath.
Safety Rules & General Information Safety and Operating Decals descriptions. Replace any missing or hard-to-read decals and use care when washing or cleaning the unit. Decal part numbers can be found in the unit parts manual at www.generac.com. See Figure 1-1. This unit features numerous safety and operating decals. These decals provide important operating instructions and warn of dangers and hazards.
Safety Rules & General Information This page intentionally left blank.
General Information and Setup Section 2: General Information and Setup Specifications ENGINE BATTERY Generac G-Force 12V, 9 Ah BED Capacity – ft3 (m3) 8 (0.23) Capacity – lbs (kg) 800 (362.9) Bed height – in (cm) 20 (50.8) Construction Cellular core high strength molded polyethylene Dump angle 60° Latch mechanism N/A (Actuator latches the bed) TRANSMISSION Forward 3: 3.7 (5.9) Speed – mph (km/h) Forward 2: 2.4 (3.9) Forward 1: 1.3 (2.1) Reverse: 1.4 (2.
General Information and Setup Controls and Features D E P Q C B A F R U S T O N G M L K J I H 006218 Figure 2-1.
General Information and Setup Know Your Powerwagon WARNING Consult Manual. Read and understand manual completely before using product. Failure to completely understand manual and product could result in death or serious injury. (000100a) See Figure 2-1. Be familiar with the controls and features of the unit prior to operation. Read this manual thoroughly before assembling and operating this unit. Save this manual for future and immediate reference.
General Information and Setup NOTE: See Figure 2-5. The actuator bracket (C) must be positioned on the right hand side of the frame, with the mounting hole towards the actuator to complete this procedure. Tailgate Installation 1. See Figure 2-7. Install tailgate onto front of bed assembly. C 006170 Figure 2-7. Tailgate Installation 006168 Figure 2-5. Actuator Bracket 3. Secure rear of actuator bracket to frame and dump arm with a 5/16 in - 18 x 3 in flange bolt and locknut.
General Information and Setup 1. Remove black factory panel insert from control panel. NOTE: Do not place sensor wire on or near a hot surface. 2. Insert panel adapter from kit into open hole in control panel. Verify flange of adapter is secured completely. Engine Fluid Requirements 3. Insert meter into panel adapter until it snaps into place. Meter flange should be flat against the face of the adapter. Engine Oil 4. See Figure 2-9.
General Information and Setup 2. See Figure 2-11. Remove oil dipstick/fill cap (A). B 3. Fill tank with fresh, unleaded gas (with a minimum 85 octane rating) to 0.25 in (6.4 mm) from the bottom of the fill neck to allow for fuel expansion. 4. Install fuel fill cap. Connecting Battery Cables 1. Remove protective caps from battery terminals. 2. See Figure 2-12. Connect red battery cable to red battery terminal, and connect black battery cable to black battery terminal. A Figure 2-11.
General Information and Setup High Altitude Replacement Kit The standard carburetor air-fuel mixture is too rich at high altitudes for this unit. Performance decreases and fuel consumption increases at high altitudes. A rich mixture also fouls the spark plug and causes hard starting. Operation for extended periods of time at an altitude that differs from what the engine was certified for may increase emissions. Install an altitude kit, when required, when operating at higher altitudes.
General Information and Setup This page intentionally left blank.
Operation Section 3: Operation Operation and Use Questions Electric Starting Call Generac Customer Service at 1-888-GENERAC (1888-436-3722) with questions or concerns about unit operation and maintenance. Before Starting Engine CAUTION Equipment Damage. Do not continuously crank engine for more than ten seconds. Doing so will lead to overdischarge of batteries and starter seizure. (000230) WARNING CAUTION Equipment damage.
Operation Stopping NOTE: In an emergency situation, release operator presence lever to stop unit. 1. Release traction drive lever. 2. Set shift lever to neutral. 3. Release operator presence lever. 4. Set parking brake. 5. Set throttle control lever to slow (turtle). 6. Turn key to stop and remove key. Operating CAUTION Equipment damage. Always release the traction drive lever before shifting gears. Failure to do so could result engine and transmission damage. (000412) 4.
Operation Slopes and Uneven Terrain Unloading Bed IMPORTANT NOTE: Never dump load while on a slope. WARNING Personal injury. Use caution when operating unit over uneven terrain or slopes. Failure to do so could result in death, serious injury, equipment or property damage. (000460) WARNING Loss of control. Do not park the unit on a steep grade or slope, even if using a parking brake. The unit could suddenly roll, move, or tip, which could cause death, serious injury, property or equipment damage.
Operation This page intentionally left blank.
Maintenance and Troubleshooting Section 4: Maintenance and Troubleshooting Maintenance Regular maintenance will improve performance and extend engine/equipment life. Generac Power Systems, Inc. recommends that all maintenance work be performed by an Independent Authorized Service Dealer (IASD). Regular maintenance, replacement, or repair of the emissions control devices and systems may be performed by any repair shop or person of the owner’s choosing.
Maintenance and Troubleshooting Procedure Before Each Use Check engine oil level Inspect general equipment condition Verify tire pressure Inspect operator presence lever Every 25 Hours Lubricate caster wheel grease fittings Clean air filter and pre-cleaner Check parking brake adjustment Inspect belt tension and condition Inspect cable connections Clean engine exterior and cooling fans Change engine oil and filter 1st time 5 hours Every 100 Hours Replace spar
Maintenance and Troubleshooting Lubrication Changing Engine Oil Caster Wheel Lubrication WARNING See Figure 4-1. Grease the four fittings (A) with #2 lithium grease every 25 hours of operation. Risk of burns. Allow engine to cool before draining oil or coolant. Failure to do so could result in death or serious injury. (000139) WARNING Skin irritation. Avoid prolonged or repeated contact with used motor oil. Used motor oil has been shown to cause skin cancer in laboratory animals.
Maintenance and Troubleshooting Inspecting Air Filter WARNING Explosion and fire. Never clean air filter element with gasoline or low flash-point detergents. Doing so could result in death, serious injury, or equipment damage. (000580) Proceed as follows to service the air filter. 1. See Figure 4-4. Remove air cleaner cover (A). Do not allow dirt or debris to fall into air cleaner base opening. 008419 Figure 4-5. Spark Plug Gap B 6.
Maintenance and Troubleshooting A D 006181 C E 006191 Figure 4-9. Belt and Pulley System Figure 4-7. Wheel Retaining Ring 3. Align groove in tire hub to key and slide tire onto axle. 4. Install washer and tire retaining ring. 6. See Figure 4-10. Install new belt. Route belt between idler/tensioner pulleys using belt guides (F). Removing and Replacing Belt WARNING Accidental start-up. Disconnect negative battery terminal before servicing to prevent accidental engine rotation.
Maintenance and Troubleshooting Brake Arm Adjustment NOTE: Proceed to Brake Cable Adjustment if brake arm adjustment does not produce desired results. 1. Turn brake arm adjustment nut (A) one-quarter turn clockwise to tighten brakes. B 1. Place unit on a firm, level surface in a clean work area. Do not engage parking brake. Chock wheels to prevent movement. 2. Locate brake caliper at right/front of unit. 3. See Figure 4-12. Remove cable bracket bolt (A). C A C A B 006182 Figure 4-12.
Maintenance and Troubleshooting Adjusting Shift Cables G Shift cables may need adjustment if there is “play” in the wheel speed lever, or if lever is no longer aligned with wheel speed label. Proceed as follows to adjust shift cables: 1. Locate shift cable adjustment nuts on shift lever end of cable. 2. See Figure 4-16. Loosen top cable jam (A) nut. C 006193 H A Figure 4-14. Brake Caliper 7. Install new brake pad into cavity and hold in place while installing brake disc. B 8.
Maintenance and Troubleshooting Connecting Battery to Trickle Charger WARNING Accidental Start-up. Disconnect the negative battery cable, then the positive battery cable when working on unit. Failure to do so could result in death or serious injury. (000130) WARNING Environmental Hazard. Always recycle batteries at an official recycling center in accordance with all local laws and regulations. Failure to do so could result in environmental damage, death or serious injury.
Maintenance and Troubleshooting Troubleshooting Symptom Possible Cause Inspect throttle travel and adjustment. Dirty air filter; replace air filter. Engine lacks power or not running smoothly Dirty or cracked spark plug; replace spark plug. If spark plug is oily, remove spark plug and hold a rag over spark plug hole. Pull recoil cord several times to blow out any oil in the cylinder. Wipe off spark plug and install. Old fuel; drain and replace fuel. Add stabilizer if fuel is kept for a month or longer.
Maintenance and Troubleshooting This page intentionally left blank.
Maintenance and Troubleshooting This page intentionally left blank.
Maintenance and Troubleshooting This page intentionally left blank.
Part No. 10000024630 Rev. A 06/04/18 ©2018 Generac Power Systems, Inc. All rights reserved Specifications are subject to change without notice. No reproduction allowed in any form without prior written consent from Generac Power Systems, Inc. Generac Power Systems, Inc. S45 W29290 Hwy. 59 Waukesha, WI 53189 1-888-GENERAC (1-888-436-3722) www.generac.
