Dirty hand tools 101872 Operation Manual

All Terrain Power Cart

!

MODEL # 101872

Operation Manual

is safety alert symbol identies important safety messages in
this manual. Failure to follow this important safety information
may result in serious injury or death.

Part # 101873 Rev A

For Service or Questions

Call 1-877-487-8275

720-287-5182

www.dirtyhandtools.com

Dirty Hand Tools® is a brand of

1100 W 120th Ave, Suite 600

Westminster, CO 80234 • 720-287-5182

Table of Contents

Important Safety Information

Intended Use ..............................................................................4

Personal Protective Equipment ..................................................4

General Safety ............................................................................5

Safety Decals ..............................................................................6

Unpacking .....................................................................................7

Assembly ........................................................................................8

Components ................................................................................12

Operation Controls .....................................................................13

Filling with Gasoline and Oil .....................................................14

Operation ....................................................................................15

Maintenance ...............................................................................18

Troubleshooting ..........................................................................22

Storage .........................................................................................23

Warranty & Specications .........................................Back Cover

3

Important Safety Information

!

WARNING

WARNING: Read and thoroughly understand all instructions

and safety information before assembling or operating this All
Terrain Power Cart. Failure to do so may cause serious injury or
death. Do not allow anyone to operate this equipment who has
not read this manual. As with all power equipment, an All Terrain
Power Cart can be dangerous if assembled or used improperly.
Do not operate this equipment if you have doubts or questions
concerning safe operation.

Call our customer service department at 720-287-5182,
1-877-487-8275, or visit www.dirtyhandtools.com if you have any
questions or concerns about the safe operation of this equipment.

!

DANGER

Intended Use

Do Not Use the Power Cart for any purpose other than for which
it was designed. Any other use is unauthorized and may result in
serious injury or death.

Personal Protective Equipment

When operating this Power Cart it is essential that you wear safety
gear including goggles or safety glasses, adequate clothing and
tight fitting gloves (no loose cuffs or draw strings). Always wear ear
plugs or sound deafening headphones to protect against hearing
loss when operating this Power Cart. Always wear sturdy footwear.
Never wear sandals, sneakers or open shoes, and never operate the
Power Cart with bare feet. Do not wear loose clothing that might
get caught in moving parts.

!

CAUTION

Whenever you leave the operating position to unload or make

adjustments always shut o the engine and wait ve (5) minutes

to allow parts to cool. Remove the key or disconnect the spark

plug wire and keep the wire away from the spark plug to prevent

accidental starting.

4

Important Safety Information

General Safety

Failure to follow warnings, cautions, assembly and operation
instructions in the Operation Manual may result in serious injury
or death.

!

DANGER

READ THE OPERATION MANUAL BEFORE

OPERATION.

• Do not permit children to operate this equipment at any time.

Do not permit others that have not read and understood the
complete Operation Manual to operate this equipment.

• Keep all people and pets away from the work area when

operating the Power Cart.

• Do not operate the Power Cart when under the influence of

alcohol, drugs or medication.

• Do not allow a person who is tired or otherwise impaired or not

completely alert to operate the Power Cart.

!

DANGER

CAREFULLY INSPECT THE AREA TO BE TRIMMED

AND REMOVE ALL FOREIGN OBJECTS.

• Always operate the Power Cart from the control panel.

• Never stand or sit on the machine with engine running.

• Always turn the engine off when unloading.

• Never, under any conditions, remove, bend, cut, fit, weld, or

otherwise alter standard parts on the Power Cart.

• Use caution when operating on slopes.

• Do not operate on slopes greater than 20 degrees.

• Be cautious when using the Power Cart around obstacles such as

fencing, wires, ropes, or other material that can become entangled
within the Power Cart’s tracks.

• Do not exceed the recommended load limit of 705 lbs.

5

Important Safety Information

• Never run the engine in an enclosed area or without

proper ventilation as the exhaust from the engine
contains carbon monoxide, which is an odorless, tasteless,
and deadly poisonous gas.

• Fill the gasoline tank outdoors with the engine off and

allow the engine to cool completely.

• Do not operate the engine with the air cleaner or cover

over the carburetor air-intake removed, except for
adjustment. Removal of such parts could create a fire
hazard.

• e muer and engine become very hot with use and

can cause a severe burn; do not touch. Allow the engine
to cool before refueling, doing maintenance, or making
adjustments.

WARNING

READ MANUAL

Safety Decals

Safety labels on the Power Cart are to remind you of
important information while you are operating the
unit. Make sure all safety warning decals are attached
and in readable condition. Replace missing or defaced
decals. Contact Dirty Hand Tools at 1-877-487-8275 for
replacement decals.

DANGER

AVOID CONTACT

WITH

MOVING PARTS

DO NOT STAND ON

MACHINE

DANGERCAUTION

TO AVOID

SERIOUS INJURY

KEEP AWAY FROM

PINCH POINTS

MAXIMUM LOAD CAPACITY 661 LBS

CAUTION

READ MANUAL

BEFORE OPERATION

DANGER

USE CAUTION ON

SLOPES

KEEP IN GEAR

ALL TERRAIN POWER CART

CAUTION

DO NOT SIT

OR RIDE ON

POWER CART

RELEASE
HANDLE TO
DUMP LOAD

LOWER BOX

TO LOCK

IN PLACE

DANGER

UNEVEN SURFACE

COULD CAUSE

ROLL OVER

104949

CARBON

MONOXIDE

POISON

DO NOT USE

INDOORS

CAUTION

HOT SURFACES

KEEP

DISTANCE

OPERATE STEERING

LEVERS AT REDUCED

SPEED ONLY

6

Unpacking

1. Remove the screws on the top of the container and set lid aside.

2. Remove the packing materials and contents.

3. Remove the end of the container and walk the Main Power
Cart Assembly out of the container and onto a level surface.

Contents

1. Main Power Cart Assembly with engine

2. Handlebar Assembly

3. Tipping Handle

4. Extendable Side

5. Engine Guard

6. Extendable Side

7. Bottom Panel

8. Rear panel

9. Operation Manual

10. Hardware

1

4

5

6

7

3

2

16 238

1

10

2

16

A

2

4 35

M10 20 4

8

9

M8 25 2

M8 35 2

M8 30 2

B

C

6

D

7

Assembly

Mounting the Bottom Panel to the Power Cart

Position the bottom panel inside of the mounting
bracket. Align the holes through the mounting bracket
and insert the long retaining pin through the holes.
Secure with a flat washer and a cotter pin at either end.

Retaining Pin, 16mm dia. x 238mm (1 qty.)

Flat Washer, 16mm (2 qty.)

Cotter Pin, 4mm x 35mm (2 qty.)

8

Assembly

Mounting the Handlebars to the Power Cart

Align the holes in the handlebar assembly with the holes
in the mounting bracket on the Power Cart. Secure each
side with a lock washer, flat washer and M10 x 20mm

socket head bolt.

Socket Head Bolt, M10 x 20mm (4 qty.)
Lock Washer, M10 (4 qty.)
Flat Washer, M10 (4 qty.)

Hex Bolt, M8 x 25mm (2 qty.)
Lock Washer, M8 (2 qty.)
Flat Washer, M8 (2 qty.)

9

Assembly

Mounting the Engine Guard to the Power Cart

Place the engine guard inside of the mounting
bracket aligning the holes in each. Secure the left
side with two M8 x 30mm hex bolts, four washers
and two hex nuts.

Mounting the Tipping Handle to the Power Cart

Mount the tipping handle on the right hand side
aligning with the holes in the mounting bracket.
Secure with two M8 x 35 mm hex bolts, four

washers and two hex nuts.

ENGINE

GUARD

TIPPING

HANDLE

Hex Bolt, M8 x 35mm (2 qty.)

Flat Washer, M8 (2 qty.)

Hex Nut, M8 (2 qty.)

Hex Bolt, M8 x 30mm (2 qty.)

Lock Washer, M8 (2 qty.)

Flat Washer, M8 (2 qty.)

10

Assembly

Mounting the Extendable Side Panels to the Power Cart

Insert the extendable side panels into the mounting slots
on the bottom panel and secure with L-Retaining pins and

lock nuts in six places

L -Retaining Pin (6 qty.)

Lock Nut (6 qty.)

11

Components

CLUTCH

CONTROL

LEVER

ENGINE
SWITCH

THROTTLE

CONTROL

RIGHT

STEERING

LEVER

LEFT

STEERING

LEVER

GEAR

SELECTION

LEVER

DUMP

BOX

TIPPING

HANDLE

TRACKS

GEAR

BOX

12

Operation Controls

Engine Switch

e engine switch must be in the on position for the
engine to start and run.

rottle Control

e throttle controls the speed of the engine and can be
adjusted between low (L) and high (H).

Clutch Control Lever

Squeeze the clutch control to engage the clutch, release
the lever to disengage the clutch.

Left Steering Lever

Depress the lever to turn to the left.

Right Steering Lever

Depress the lever to turn to the right.

Gear Selection Lever

Controls the forward or reverse movement of the Power
Cart. e Power Cart has three forward gears and one
reverse gear.

Tipping Handle

Control the tipping of the dump cart. Pull the tipping
handle up to release the dump box’s locking device and
to raise the dump box. When the dump box is lowered
completely down towards the Power Cart the locking
mechanism automatically engages on the tipping handle
to lock the dump box in place to prevent dumping.

13

Filling with Gasoline and Oil

!

WARNING

ADD OIL BEFORE STARTING THE ENGINE

e Power Cart is shipped without uids installed.

Keep the caps on the fuel and oil fills until you are ready to pour

either gasoline or oil into the correct fill.

Requires approximately 20 ounces of SAE 10W30 engine oil.

1. Place the machine on a level surface and initially add 1/2 of the
SAE 10W30 high detergent oil into the oil fill and wait one
minute for the oil to settle.

2. Check the dipstick and continue adding a few ounces of oil at a
time, rechecking the dipstick until the oil reaches the fill mark.
Be careful not to overfill.

3. Fill the fuel tank with fresh, unleaded gas (85+ Octane), to 1/2”
from the top of the ll neck to allow for expansion. Be careful not
to overll and reinstall the cap before starting the engine.

!

SAE VISCOSITY GRADES

30W

10W - 30W

5W - 30W

-20 0 20 40 60 80 100°F

AVERAGE OUTSIDE TEMPERATURE

WARNING

ALWAYS FILL THE TANK WITH

ENGINE OFF AND COOL.

ALWAYS CHECK THE OIL LEVEL

BEFORE OPERATING.

Allow the engine to cool for at least two minutes before removing
the fuel cap. Use caution as engine oil, muffler and other
components may be hot to the touch. To avoid fire danger never
add fuel to a hot engine.

Before performing any adjustments to the Power Cart or any
maintenance, stop the engine, wait five minutes to allow parts to
cool. Disconnect the spark plug wire, keeping it away from the
spark plug. Contact with internal rotating parts may cause serious
personal injury. Never put hands or feet on or between the track
rollers.

14

Engine

ON/OFF

Throttle

Switch

Operation

Starting the Engine

A more detailed description of the engine operation
and all related precautions and procedures can be
found in the Engine Manual packed separately
with the Power Cart.

Follow the procedure below for cold starts:

1. Turn choke lever on the engine to the CLOSED position.

2. Set the throttle lever on the handlebar at halfway position.

3. Turn the engine switch on.

4. Pull the starting rope slowly several times to allow the
gasoline to flow into the engine’s carburetor. en hold the
start handle firmly and pull rope out a short distance until
you feel some resistance. en pull the rope smoothly and
briskly, and allow rope to return gently. Do not let the rope
snap back. If necessary, pull the rope several times until the
engine starts.

5. Allow the engine to run for several seconds to warm up.
en, gradually move choke lever to “OPEN” position.

Recoil

Starter

Restarting a warm engine does not require use of the choke,
so follow the same steps above with the choke lever set to the
OPEN position.

Stopping the Engine

To stop the engine in an emergency, simply turn
the engine switch to the OFF position. Under
normal conditions, use the following procedure.

1. Move the throttle lever to the SLOW position.

2. Let engine idle for one or two minutes.

3. Turn the engine switch to the OFF position.

4. Turn the fuel valve lever to the OFF position.

!

CAUTION

Do not move the choke control to stop the engine.

is may result in engine backre or

damage to the engine may occur.

15

Operation

Operating

After engine warms up, pull throttle lever to accelerate engine
speed. Engage the required gear and slowly squeeze the clutch
control lever. If the gear does not engage right away, slowly
release the clutch lever and try again.

Changing Directions

1. To turn left, pull the left steering lever upwards.

2. To turn right, pull the right steering lever upwards.
e sensitivity of the steering increases in proportion to the
speed of the machine and that with an empty machine, a light
pressure on the lever is all that is needed to turn. When the
machine is loaded, more pressure is required.

!

CAUTION

It is recommended that the operator practice driving the Power

Cart with the dumper empty to become familiar with the

equipment’s operation before attempting to move a load.

!

DANGER

e Power Cart’s maximum capacity is 700 lbs. (317.5 kg).

To avoid tipping over when operating

on a slope use the lowest gear.

Never operate on a slope greater than 20 degrees.

Avoid sharp turns and frequent changes of direction
particularly on rough, hard terrains. Use caution when working
in adverse weather conditions (ice, heavy rain and snow) or on
types of ground that could make the Power Cart unstable.

Note that as this is a tracked vehicle, it is subject to a
considerable pitching movement when passing over bumps,
holes and steps. If the machine is stopped on a steep slope, a
block should be placed against one of the tracks.

When the clutch control lever is released, the machine will stop
and brake automatically.

16

Operation

!

DANGER

NEVER load or unload the Power Cart

while the engine is running.

A strong impact in the bucket could accidentally engage

the transmission, setting the Power Cart into motion.

Loading and Unloading

1. Position the Power Cart into the desired position for

dumping the load.

2. Turn off the engine and put the clutch lever into the

STOP position.

3. Pull the tipping handle up to release the dump box’s

locking device and raise the dump box.

4. Raise the dump box manually to dump the load.

5. Pull the tipping handle down to its original position.

When the dump box is lowered, the locking mechanism
operates, locking the dump box.

17

Maintenance

!

WARNING

TURN OFF ENGINE AND

DETACH SPARK PLUG WIRE.

Allow engine to cool before performing maintenance.

Check the Power Cart for loose screws, misalignment or binding of
moving parts, cracked or broken parts, and any condition that may
affect safe operation. Remove debris and other materials that may
have accumulated in and around the tracks. Clean after each use.
Use a premium lightweight machine oil to lubricate moving parts.

!

CAUTION

Do not use a “pressure washer” to clean the Power Cart.

Water can penetrate the machine and its transmission case and

cause damage to spindles, gears, bearings or the engine.

Transmission

e gearbox is pre-lubricated and sealed at the factory. Check oil
level every 50 hours of working. Use portable tool lithium #0 grease
such as Lubriplate 6300AA , Lubriplate GR-132, or Multifak,e.g.
EP-O.

Changing the Engine Oil

Oil should be changed when warm by unscrewing filler cap
and draining into a suitable container for disposal. When oil
is completely drained, replace filler cap and fill with standard
SAE10W30 engine oil.

Adjusting the Clutch Lever

As the clutch wears out, the lever could have a wider opening,
making it difficult to use. Adjust the cable, setting the clutch lever to
its original position using the adjustment device and counter-nut.

Adjusting the Steering Levers

If steering the unit becomes difficult, adjust the steering levers with
the special adjusters. Loosen the locknut and unscrew the adjuster to
eliminate the play in the cable, which can occur with normal wear.
Be careful not to unscrew the adjusters too much because this can
create the loss of traction. Tighten the locknut when finished.

18

Maintenance

Adjusting the Tracks

With use, tracks tend to loosen on the drive wheels. Operating
with loose tracks can cause them to slip over the driving wheel
causing it to jump its housing and cause damage.

1. To check track tightness set the Power Cart on a flat, compact
surface. Lift the machine and set it on blocks or supports so
that the tracks are approximately 4” (100mm) off of the ground.

2. Measure the sag in the tracks, by measuring the height from
the ground to the middle of the top track. Compare this with
measuring the distance from the ground to the top of the track
on the top of the wheel. e difference in the distance should
not exceed 0.4” - 0.6” (10 - 15mm). If the distance is greater,
use the tipping handle to tip the dump box and set it on blocks
that support the weight of the Power Cart.

3. Loosen locknut A. Tighten bolt B until the correct tightness
is restored. Secure bolt B by tightening locknut A thoroughly.
Return the dump box to its original position.

A

A

B

!

CAUTION

LIFTING THE POWER CART

REQUIRES TWO PEOPLE

e adjustment of the track and the brakes are
linked, therefore be careful to not over-tighten the
track causing the loss of braking ability.

If the adjustment bolt has no more adjustment left,
the tracks may have to be replaced.

B

19

Maintenance

Replacing tracks

Check the condition of the tracks periodically. If a track is
cracked or frayed, it should be replaced as soon as convenient.

1. Loosen the locknut A and bolt B shown in Adjusting the
Tracks, (page 19) to allow the tracks to be loose enough.

2. Slip the old tracks o and install the new tracks.

3. Adjust bolt B to assure correct tightness.

4. Secure bolt B by tightening locknut A thoroughly.

!

CAUTION

When removing or installing the tracks,

use caution to avoid having ngers caught

between the track and pulley.

20

Maintenance

Engine Maintenance

1. Check oil level before each use and after 8 hours of operation.

2. Change oil after first 5-8 hours of operation. Change oil while
engine is warm. Refill with new oil of recommended grade.

4. Check spark plug yearly or every 100 hours of operation.

5. Service air cleaner.

6. Keep engine and parts clean.

7. Check engine and equipment often for loose nuts and bolts.

Maximum

H

Oil Level

Set the

Spark Plug

Gap

0.6 - 0.7mm

Oil Fill/

Dipstick

L

Air Cleaner

Air Cleaner

Minimum
Oil Level

Cover

Filter

21

Troubleshooting

PROBLEM SOLUTION

Engine will not start • Add gas to gas tank

• Connect spark plug wire to spark plug

• rottle must be positioned in the middle

• Choke lever must be CLOSED to start cold engine

• Fuel line is clogged, remove, clean and replace

Engine runs rough, oods during operation • Clean or replace air cleaner

Engine is hard to start • Drain old fuel and replace with fresh. Use gas stabilizer

at end of season

• Make sure spark plug wire is securely attached to plug

• Move the throttle to the left

Engine misses or lacks power • Remove and clean fuel tank

• Clean or replace air cleaner

• Improper carburetor adjustment, take to authorized
engine service center

• Replace spark plug and adjust gap

• Drain and rell gas tank and carburetor

Engine stops suddenly • Low quality or deteriorated gasoline, drain and replace

• Spark plug wire damaged or loose

• Defective fuel cap creating a vacuum

• Improper idle speed, move throttle to the right

Engine Overheats • Engine oil is too low, check dipstick and add oil

• Dirty air lter, clean and replace

Engine stalls when shifting transmission gears • Release clutch lever before shifting gears

Power Cart moves forward during starting • Clutch lever must be released

Power Cart is not braking properly or is hard to turn • e steering lever(s) need adjustment (see page 18)

• e brake(s) are wet, allow the brakes to dry

• e dump box is overloaded, reduce the load

e Power Cart’s track has slipped o • Adjust the track tension (see page 19)

• Replace the track if it is broken or excessively worn

Power Cart moves too slowly • Reduce the load

• Put transmission into a higher gear

Power Cart does not move with the engine running • Make sure that the transmission is not between gears

• Tracks are not tight enough, stop engine and adjust
track tension (see page 19)

22

Storage

To store the Power Cart for an extended period:

1. Drain the fuel tank completely. Stored fuel containing ethanol
or MTBE can start to go stale in 30 days. Stale fuel has high
gum content and can clog the carburetor and restrict fuel flow.
Start the engine and allow it to run until it stops. is ensures
no fuel is left in the carburetor.

2. While the engine is still warm, drain the oil from the engine.
Refill with fresh oil of the grade recommended in the Engine
Manual.

3. Use a clean cloth to clean o the outside of the machine and to
keep the air vents free of obstruction.

4. Inspect for any loose or damaged parts. Repair or replace
damaged parts and tighten loose screws, nuts or bolts.

5. Store your unit on at ground in a clean, dry building that has
good ventilation.

6. Do not use strong detergents or petroleum based cleaners
when cleaning plastic parts. Chemicals can damage plastics.

!

CAUTION

Do not store the Power Cart with fuel in a non-ventilated area

where fuel fumes may reach ame, sparks,

pilot lights or ignition sources.

23

Warranty & Specications

IMPORTANT NOTICE

We, the manufacturer, reserve the right to change the product and/
or specifications in this manual without notification. e manual is for
information usage only and the pictures and drawings depicted herein are
for reference only.

Warranty Repair and Service

Do not return this product to the store for warranty issues or repair. Call
our customer service department at 720-287-5182, 1-877-487-8275, or
visit www.dirtyhandtools.com for the location of the nearest service center.

Record the information below for future reference.

Model No.

Serial No.

Date of Purchase

Place of Purchase

Specications

SKU/Part No. 101872

Description All Terrain Power Cart
Engine 6.5 HP /196cc Engine*

EPA/50 State Approved
Engine Fuel Capacity 0.95 gallons (3.6 liters)
Engine Oil Capacity 20.3 ounces (0.6 liters)
Transmission 3 Forward Speeds /1 Reverse Speed
Load Capacity 700 Lbs. (317.5 kg)
Cargo Dimensions 36”L x 24”W x 8” H
Trac ks 7” Width
Dumping Manually up to 60° angle
Dimensions 44.7”L x 29.5”W x 29.5” H
Weight 392.4 Lbs. (178 kg)
Warranty 2 Year / 2 Year Limited Warranty

*As rated by engine manufacturer
** Not included, shipped without engine oil

Dirty Hand Tools® is a brand of

1100 W 120th Ave., Suite 600

Westminster, CO 80234 • 720-287-5182

For Service or Questions

Call 1-877-487-8275

720-287-5182

www.dirtyhandtools.com