DR PRO-XL Safety And Operating Instructions Manual
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D R
®
POWERWAGON
SAFETY & OPERATING INSTRUCTIONS
Models: Premier
Pro
Pro-XL
Serial No.
Order No.
Original Language
DR Power Equipment
Toll-free phone: 1-800-DR-OWNER (376-9637)
Fax: 1-802-877-1213
Website: www.DRpower.com
Read and understand this manual and all instructions before operating the DR POWERWAGON.
Table of Contents
Chapter 1: General Safety Rules ............................................................................................................................................................ 3
Chapter 2: Setting Up The DR POWERWAGON .................................................................................................................................. 7
Chapter 3: Operating The DR POWERWAGON ................................................................................................................................... 17
Chapter 4: Maintaining The DR POWERWAGON ............................................................................................................................... 21
Chapter 5: Troubleshooting .................................................................................................................................................................. 29
Chapter 6: Parts Lists and Schematic Diagrams .................................................................................................................................. 32
Conventions used in this manual
This indicates a hazardous situation, which, if not followed, could result in death or serious injury.
This indicates a hazardous situation, which, if not avoided, could result in minor or moderate injury.
This information is important in the proper use of your machine. Failure to follow this instruction could result in damage to your machine or property.
Figure 1
Serial Number
Label
Serial Number and Order Number
A Serial Number is used to identify your machine and is located on the Serial
Number Label on your machine. An Order Number is used to check and maintain your order history and is located on the upper left portion of your packing slip. For your convenience and ready reference, enter the Serial
Number and Order Number in the space provided on the front cover of this manual.
Additional Information and Potential Changes
DR Power Equipment reserves the right to discontinue, change, and improve its products at any time without notice or obligation to the purchaser. The descriptions and specifications contained in this manual were in effect at printing. Equipment described within this manual may be optional. Some illustrations may not be applicable to your machine.
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Chapter 1: General Safety Rules
Read this safety & operating Instructions manual before you use the DR POWERWAGON. Become familiar with the operation and service recommendations to ensure the best performance from your machine. If you have any questions or need assistance, please contact us at www.DRpower.com or call toll-free 1-800-DR-OWNER (376-9637) and one of our Technical Support
Representatives will be happy to help you.
Labels
Your DR POWERWAGON carries prominent labels as reminders for its proper and safe use. Shown below are copies of all the
Safety and Information labels that appear on the equipment. Take a moment to study them and make a note of their location on your POWERWAGON as you set up and before you operate the unit. Replace damaged or missing safety and information labels immediately.
#13758
#37055
#38555
#38553
#38552
#38554
#15342
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Protecting Yourself and Those Around You
This is a high-powered machine, with moving parts operating with high energy at high speeds. Use proper clothing and safety gear when operating this machine to prevent or minimize the risk of severe injury. You must operate the machine safely. Unsafe operation can create a number of hazards for you. Always take the following precautions when operating this machine:
Wear shoes with non-slip treads when using your DR POWERWAGON. If you have safety shoes, we recommend wearing them. Do not use the machine while barefoot or wearing open sandals.
Avoid wearing loose clothing or jewelry, which can catch on the machine’s moving parts.
Use ear protectors or ear plugs rated for at least 20 dba to protect your hearing.
Never allow people who are unfamiliar with these instructions to use the DR POWERWAGON. Allow only responsible individuals who are familiar with these rules of safe operation to use your machine.
Never place your hands, feet, or any part of your body near or under any moving part while the machine is running.
To be safe, do not operate the machine near small children or pets, and never allow children to operate the DR
POWERWAGON.
The muffler and engine become very hot and can cause a severe burn; do not touch.
Never, under any conditions, remove, bend, cut, fit, weld, or otherwise alter standard parts on the DR POWERWAGON. This includes all shields and guards. Modifications to your machine could cause personal injuries and will void your warranty.
Slope Operation
Slopes are a major factor related to slip and fall accidents, which can result in severe injury. All slopes require caution. If you feel uneasy on a slope, do not use the DR POWERWAGON on it. Always take the following precautions when using this machine on slopes:
Always:
Traverse up and down the face of slopes; never across. Exercise extreme caution when changing direction on slopes.
Watch for holes, ruts, or bumps in the landscape.
Use 1st gear on slopes with a maximum load of 800 lbs.
Never:
Operate near drop-offs, ditches, or embankments; you could lose your footing or balance.
Operate on slopes greater than 15 degrees, or any excessively steep slopes.
Operate on wet, or slippery slopes; reduced traction could result in slipping.
Park the DR POWERWAGON on a steep grade or slope.
Safety with Children and Pets
Tragic accidents can occur if the operator is not alert to the presence of children and pets. Children are often attracted to the machine and the hauling activity. Never
assume that children will remain where you last saw them.
Keep children out of the work area and under the watchful care of a responsible adult.
Be alert and always turn off the DR POWERWAGON engine if children or pets enter the work area.
Before, and while moving backwards, look behind, and down for small children and pets.
Never allow children to operate the DR POWERWAGON.
Use extra care when approaching blind corners, shrubs, trees, or other objects that may obscure your vision.
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Safety with Gasoline-Powered Machines
Gasoline is a highly flammable liquid. Gasoline also gives off flammable vapor that can be easily ignited and cause a fire or explosion. Never overlook the hazards of gasoline. Always follow these precautions:
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.
Store all fuel and oil in containers specifically designed and approved for this purpose and keep away from heat and open flame, and out of the reach of children.
Fill the gasoline tank outdoors with the engine off and allow the engine to cool completely. Do not handle gasoline if you or
anyone nearby is smoking or if you are near anything that could cause it to ignite or explode. Replace the fuel tank and fuel container caps securely.
If you spill gasoline, do not attempt to start the engine. Move the machine away from the area of the spill and avoid creating any source of ignition until the gas vapors have dissipated. Wipe up any spilled fuel to prevent a fire hazard and properly dispose of the waste.
Allow the engine to cool completely before storing the DR POWERWAGON in any enclosure. Never store the machine with gas in the tank or a fuel container near an open flame or spark, such as a water heater.
Never make adjustments or repairs with the engine running. Disconnect the spark plug wire and keep the wire away from the spark plug to prevent accidental starting.
Never check for an ignition spark with the spark plug or spark plug wire removed. Use an approved spark tester.
Never tamper with safety devices. Check their proper operation regularly.
Do not change the engine governor settings or modify the engine speed. Modifications will void your warranty.
To reduce fire hazard, keep the engine cooling fan and muffler area free of debris build-up such as leaves, grass, oil, grease or any other combustible material.
Never operate the engine without the muffler. Inspect the muffler periodically and replace if necessary. If equipped with a muffler deflector, inspect the deflector periodically and replace if necessary.
Never 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. Do not use flammable solutions to clean air filter.
Check fuel lines and fittings frequently for cracks or leaks, replace if necessary.
Replace rubber fuel lines and grommets when worn or damaged and after 5 years of use.
General Safety
The DR POWERWAGON must be operated safely to prevent or minimize the risk of minor or moderate injury. Unsafe operation can create a number of hazards for you. Always take the following precautions when operating this machine:
Keep in mind that the operator or user is responsible for accidents or hazards occurring to other people, their property, and themselves.
Your DR POWERWAGON is not a plaything. Exercise extreme caution at all times. The design of this machine is to haul material. Do not use it for any other purpose.
Give complete and undivided attention to the job at hand. Before you use your new machine, be sure you know how to engage the parking brake and stop the DR POWERWAGON at a moment's notice.
Always operate the DR POWERWAGON from behind the handlebars, never from the side.
Never use the DR POWERWAGON to drag or tow items.
Do not overload the DR POWERWAGON. Be careful of top-heavy loads. The higher the load, the more chance of tipping over the machine. Loads may shift during operation; to be safe, secure your loads and even them out when possible. The
maximum load is 500 lbs. (Premier), 700 lbs. (Pro) and 800 lbs. (Pro-XL).
Use 1st gear with loads over 300 lbs. And on slopes. Excessive speed can be dangerous. Operate the machine in the lowest gear that is satisfactory to do the job. contact us at
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General Safety (Continued)
Use caution when moving downhill and braking. Apply the parking brake slowly to avoid tipping forward.
When shifting to reverse, be careful to avoid tipping as the swivel wheel changes direction.
Watch for traffic when operating near roadways.
Never allow people or pets to ride in the DR POWERWAGON.
If the machine should start making an unusual noise or vibration, stop the engine and wait five (5) minutes to cool. Vibration is generally a warning of trouble. Disconnect the spark plug wire and inspect for damaged parts. Clean and repair and/or replace damaged parts.
Built-in safety features, such as the operator presence system, are effective only when maintained and kept in place.
Always keep the equipment in a good safe operating condition. Always make certain nuts and bolts are tight and always use the supplied self-locking hardware; do not substitute. Use only approved DR parts.
Use the DR POWERWAGON only in daylight.
While using the machine, do not hurry or take things for granted. When in doubt about the equipment or your surroundings, stop the machine and take the time to look things over. Make sure that you have 100% control of the machine at all times.
Never leave the DR POWERWAGON unattended with the engine running.
Do not operate the machine when under the influence of alcohol, drugs, or medication.
See manufacturer’s instructions for proper operation and installation of accessories. Only use accessories approved by DR
Power Equipment.
California Proposition 65
California Proposition 65:
Engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects, and other reproductive harm.
This product contains or emits chemicals known to the state of California to cause cancer, birth defects, and other reproductive harm.
A Note to All Users
Under California law, and the laws of some other states, you are not permitted to operate an internal combustion engine using hydrocarbon fuels without an engine spark arrester. This also applies to operation on US Forest Lands. All DR
®
POWERWAGONS shipped to California, New Mexico and Washington State are provided with spark arresters. Failure of the owner or operator to maintain this equipment in compliance with state regulations is a misdemeanor under California law and may be in violation of other state and/or federal regulations. Contact your State Park Association or the appropriate state organization for specific information in your area.
No list of warnings and cautions can be all-inclusive. If situations occur that are not covered by this manual, the operator must apply common sense and operate this DR
®
POWERWAGON in a safe manner. Contact us at www.DRpower.com or call 1-800-
DR-OWNER (376-9637) for assistance.
Additional Information and Potential Changes
Country Home Products, Inc. reserves the right to discontinue, change, and improve its products at any time without notice or obligation to the purchaser. The descriptions and specifications contained in this manual were in effect at printing. Equipment described within this manual may be optional. Some illustrations may not be applicable to your machine.
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Chapter 2: Setting Up The DR POWERWAGON
It may be helpful to familiarize yourself with the controls and features of your DR POWERWAGON as shown in Figure 2 before beginning these procedures. If you have any questions at all, please feel free to contact us at www.DRpower.com.
DR PREMIER POWERWAGON Controls and Features
Key Switch
Shift Lever
Maintenance Meter
Location
(Optional Accessory)
Operator Presence
Lever
Brake Lever
Brake Lock
Premier Bed
Assembly
Dump Handle
(Premier and Pro
Standard)
Dump Arm
Fuel Cap
Transaxle
Traction Drive
Lever
Throttle
Control
Caster Wheels
Manual Recoil
Starter Handle
Oil Fill
Brake Pad
Assembly
Figure 2a
All-Terrain Tires
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DR PRO and PRO-XL POWERWAGON Controls and Features
Key Switch
Shift Lever
Electric Dump Switch
(Pro Optional)
(Pro-XL Standard) Maintenance Meter
Location
(Optional Accessory)
Throttle
Control
Operator Presence
Lever
Brake Lever
Pro and
Pro-XL Bed
Brake Lock
Traction Drive
Lever
Battery
(Electric-starting model only)
Caster Wheels
Oil Fill
Fuel Cap
Transaxle
Dump Arm
Manual Recoil
Starter Handle
Brake Pad
Assembly
Actuator
(Pro Optional)
(Pro-XL Standard)
Figure 2b
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All-Terrain Tires
Sidewall and
Tailgate
Specifications
Engine
Briggs & Stratton
(See Engine Owner’s Manual for Engine Specifications)
BATTERY
N/A
BED
Capacity - Volume (Cu Ft) 5.2
Capacity - Weight (Lbs) 500
8
700
Briggs & Stratton
(See Engine Owner’s Manual for Engine Specifications)
12V, 9 Ah
Briggs & Stratton
(See Engine Owner’s Manual for Engine Specifications)
12V, 9 Ah
8
800
Dump Angle (Degrees)
Latch Mechism
TRANSMISSION
Speeds
Brake
FRAME
Frame Type
Skid Plate
ACTUATOR
(Hdpe)
60°
Molded Polyethylene
60°
Cellular Core High Strength
Molded Polyethylene
60°
Intergrated Latch & Handle Intergrated Latch & Handle N/A (Actuator Latches The
Bed)
Forward 3: 3.7 Mphmmnm
Forward 2: 2.4 Mph
Forward 1: 1.3 Mph
Reverse: 1.4 Mph
Forward 3: 3.7 Mph
Forward 2: 2.4 Mph
Forward 1: 1.3 Mph
Reverse: 1.4 Mph
Forward 3: 3.7 Mph
Forward 2: 2.4 Mph
Forward 1: 1.3 Mph
Reverse: 1.4 Mph
Transaxle Disc Brake
Tubular Steel (1.5" Diameter
X 12 Ga Thick)
9 Ga Thick
Transaxle Disc Brake
Tubular Steel (1.5" Diameter
X 12 Ga Thick)
9 Ga Thick
Transaxle Disc Brake
Tubular Steel (1.5" Diameter X
12 Ga Thick)
9 Ga Thick
Full Load Speed
(Mm/S (In/S))
Full Load Seconds/Lift N/A N/A 16.745
No Load Speed
(Mm/S (In/S))
No N/A N/A 9.962
Stroke (Mm (In)) N/A N/A 200 (7.87)
(Approximately 1 Full Capacity
Load Every 4.5 Minutes)
WHEELS
Front (Size & Type)
Rear (Size & Type)
DIMENSIONS
Overall Product Dim's
16" Diameter, 4" Width,
Snowhog Tread
16" Diameter, 4" Width,
Snowhog Tread
16" Diameter, 4" Width,
Snowhog Tread
11" Diameter, 4" Width, Rib 11" Diameter, 4" Width, Rib 11" Diameter, 4" Width, Rib
66.5 L X 33.25 W X 41 H 63.25 L X 34.5 W X 41 H 63.25 L X 34.5 W X 41 H contact us at
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2
4
Figure 4
5
4
7
8
2
Figure 5
Bolts and
Locknuts
Figure 6
Dump
Handle
6
Figure 7
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7
1
3
3
5
Handlebar
Assembly
6
1
Assembling the DR POWERWAGON
Tools & Supplies Needed:
Two 9/16" Wrenches
1/2" Wrench
1/2" Socket with Ratchet and Extension
Two 3/4" Wrenches
10" Adjustable Wrench
Parts Supplied in Product Package - PREMIER AND PRO MODELS (Figure 4
and list below):
Item # Part # Description Qty
1 ........... 38540 ....... Spring, Torsion, 360 Deg, .063" Wire, .798" OD ... 1
2 ........... 33353 ....... Bolt, Hex, Flange, 1/2-13 X 4", GR5 ....................... 1
3 ........... 38596 ....... Bolt, Hex, Flange, 3/8-16 X 1-3/4", GR5, ZP .......... 2
4 ........... 38598 ....... Bolt, Hex, Flange, 5/16-18 X 2-1/2", GR8, ZP ........ 2*
5 ........... 33335 ....... Nut, Nylon Lock, Flanged, 1/2-13 ........................... 1
6 ........... 33333 ....... Nut, Nylon Lock, Flanged, 3/8-16 ........................... 2
7 ........... 33332 ....... Nut, Nylon Lock, Flanged, 5/16-18 ......................... 2*
*Pro Model has Quantity of 4 for these items.
Parts Supplied in Product Package – PRO-XL MODEL (Figure 5 and list below):
Item # Part # Description Qty
1 ........... 37936 ....... Bracket, Actuator, Dump Arm ................................ 1
2 ........... 39084 ....... Bolt, Hex, Flange, 1/2-13 X 1-1/2", GR5, ZP .......... 1
3 ........... 38596 ....... Bolt, Hex, Flange, 3/8-16 X 1-3/4", GR5, ZP .......... 2
4 ........... 39085 ....... Bolt, Hex, Flange, 5/16-18 X 3", GR8, ZP ............... 1
5 ........... 38598 ....... Bolt, Hex, Flange, 5/16-18 X 2-1/2", GR8, ZP ........ 4
6 ........... 33335 ....... Nut, Nylon Lock, Flanged, 1/2-13 ........................... 1
7 ........... 33333 ....... Nut, Nylon Lock, Flanged, 3/8-16 ........................... 2
8 ........... 33332 ....... Nut, Nylon Lock, Flanged, 5/16-18 ......................... 5
Compare the contents of the Product Package with the “Parts Supplied in
Product Package” list above. If you have any questions please contact us at www.DRpower.com or call 1-800-DR-OWNER (376-9637) for assistance.
1.
Lift the Handlebars to the operating position and install a 3/8-16 X 1-3/4
Flange Bolt and Locknut on each side using two 9/16" Wrenches (Figure 6).
Note:
Ensure that the top Handlebar Bolts are installed in the same direction as the lower Bolts with the heads on the inside of the Handlebars.
2.
Tighten the lower Handlebar Bolts that were already in place.
Dump Handle
Mounting Bracket
Premier Bed - Assembly and Installation
If you have the Pro or Pro-Xl Model, refer to the next section “Pro and Pro-XL
Bed - Assembly and Installation”.
If you are installing the Flatbed on your POWERWAGON, proceed to the
“Flatbed Installation” section in this Chapter.
1.
Position the Dump Handle at the right rear corner of the Bed where the
Mounting Bracket is located (Figure 7).
2.
Insert one end of the Torsion Spring into the small hole in the Frame
(positioned as shown) and push it through to the hole on the other side of the Frame Tube (Figure 8).
3.
Install the 1/2-13 X 4" Flange Bolt through the Frame, Spring and Dump
Lever. Secure with the 1/2-13 Locknut using two 3/4" Wrenches. Do not over tighten.
4.
Rotate the remaining end of the Spring and secure it under the Spring Tab
(Figure 9).
5.
Remove the Locknuts from the front of the Bed Frame and use a 1/2"
Wrench to turn the Front Bed Bolts out so the end of the threads are flush with the inside of the Frame opening (Figures 10 and 11).
Note:
To ease the process of aligning the ends of the Bolts, a 10" Adjustable Wrench can be used on the Frame Tube to align the holes.
Frame
Tube
Dump
Lever
Figure 8
6.
Place the Bed on the Power Wagon with the Dump Arms inside the Frame at the front of the Bed Assembly (Figures 12).
7.
Ensure the back of the Bed Assembly is on the Bed Rest Brackets and the
Dump Lever is fully latched onto the Latch Pin (Figure 13).
Spring
Dump
Arms
Bed
Figure 9
Spring
Tab
Holes
Bolt
Figure 12
Bed Rest
Bracket
Figure 10
Locknuts
Tube
Front Bed Bolts
Figure 13
Dump
Handle
Latch
Pin
Even With
Tube (Flush)
Adjustable
Wrench
Figure 11
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Dump
Arms
Figure 14
Figure 15
Rear Bed
Support
Bolt
Front Bed
Bolts
Frame
Tube
Figure 16
Dump
Arms
5/16-18 X 2-1/2" Flange
Bolts and Locknuts
Bed
Assembly
8.
Turn the Front Bed Bolts through the Frame and Dump Arms at the front of the Bed with a 1/2" Socket and Ratchet with Extension (Figure 14).
Note:
If the Bolts are not aligning well with the holes in the Frame and Dump Arms, a 10" Adjustable Wrench can be used on the front Frame Tube to align the holes
(Figure 15).
9.
Secure the Front Bed Bolts to the Frame and Bed Supports with the four
5/16-18 Locknuts (you removed in step 5) using a 1/2" Wrench and 1/2"
Socket.
10.
Secure the rear of the Dump Arms to the Frame with two 5/16-18 X 2-1/2"
Flange Bolts and Locknuts using a 1/2" Wrench and Socket (Figure 14).
Your Premier POWERWAGON assembly is complete. Proceed to the “Check the
Tire Pressure” section in this Chapter to continue with the setup of your machine.
Pro and Pro-XL Bed - Assembly and Installation
If you are installing the Flatbed on your POWERWAGON, proceed to the
“Flatbed Installation” section in this Chapter.
PRO MODEL WITH HAND DUMP
1.
Installing the Dump Handle on the Pro Model is the same as the Premier
Model. Refer to Steps 1 through 4 of “Premier Bed - Assembly and
Installation” if you do not have the Actuator Dump option.
PRO and PRO-XL MODELS
1.
Place the Bed Assembly at the front of the machine with the Tailgate end resting on the ground (Figure 16).
2.
Move the Bed Assembly onto the Dump Arms and rotate the Bed back and onto the Dump Arms.
PRO MODEL WITH HAND DUMP
1.
Secure the Bed Frame to the Dump Arms with four 5/16-18 X 2-1/2" Flange
Bolts and Locknuts using a 1/2" Wrench and 1/2" Socket with Ratchet and
Extension (Figure 17).
PRO-XL MODEL ACTUATOR DUMP
1.
For the following steps the Actuator Bracket must be positioned on the right hand side of the Frame with the mounting hole towards the Actuator (Figure
18
).
Actuator
Bracket
Actuator
Dump
Arm
Mounting Hole
(Facing Actuator)
Figure 18
Figure 17
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2.
Secure the rear of the Actuator Bracket to the Frame and Dump Arm with a
5/16-18 X 3" Flange Bolt and Locknut using a 1/2" Wrench and 1/2" Socket with Ratchet and Extension (Figure 19).
3.
Secure the front of the Actuator Bracket with a 5/16-18 X 2-1/2" Flange Bolt using a 1/2" Wrench and 1/2" Socket with Ratchet and Extension.
4.
Secure the front/right (Figure 19) and both left side locations (Figure 20) of the Bed Frame to the Bed Supports with three 5/16-18 X 2-1/2" Flange Bolts and Locknuts using a 1/2" Wrench and 1/2" Socket with Ratchet and
Extension.
5.
Remove the Plastic Protectors (if present) from the end of the actuator
(Figure 21).
6.
Secure the end of the Actuator to the Actuator Bracket with a 1/2-13 X 1-1/2"
Flange Bolt and Locknut using two 3/4" Wrenches.
BOTH MODELS
1.
Install the Tail Gate onto the front of the Bed Assembly (Figure 22).
Note:
Ensure that the Guide Pins are fully into the Bed and that the Tabs at both sides are locked into the Side Walls.
5/16-18 X 3"
Flange Bolt and Locknut
Figure 19
5/16-18 X 2-1/2"
Flange Bolt and
Locknut
5/16-18 X 2-1/2" Flange
Bolts and Locknuts
Flatbed Installation (Figure 23)
Dump
Arm
1.
Installing the Dump Handle on the Flatbed is the same as the Premier
Model. Refer to Steps 1 through 4 of “Premier Bed - Assembly and
Installation”. See “PRO MODEL WITH HAND DUMP” to secure the
Flatbed to the Dump Arms.
2.
Installing the Actuator Bracket and attaching the Actuator to the Flatbed is the same procedures as the “Pro-XL Model Actuator Dump”. Refer to Steps
1 through 6 of “Pro-XL Model Actuator Dump”.
Figure 20
Actuator
1/2-13 X 1-1/2" Flange Bolt and Locknut
Flatbed
Figure 23
Figure 21
Tab
Tailgate
Side
Wall
Guide Pins
Figure 22
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Check the Tire Pressure
Tools Needed:
Tire Pressure Gauge
Air Compressor
Do not over inflate the tires. Inflate to the manufacturers recommended pressure found on the tires.
Valve Stem
Protective
Cap
Figure 24
1.
Remove the Valve Stem Protective Cap and check the tire pressure with a tire pressure gauge (Figure 24).
2.
If the pressure is too low, add air through the Valve Stem with an air hose.
3.
Replace the Valve Stem Protective Cap when finished.
Note:
The heavier the load, the higher the tire pressure should be. Do not go above the maximum recommended load or pressure.
Adding Oil and Gasoline
Engine Oil Capacity:
Refer to the Engine Owner’s manual for Engine capacities and specifications.
You must add oil before starting the engine. This machine is shipped without oil. Traces of oil may be in the reservoir from factory testing, but you must add oil before starting the engine. Fill the reservoir slowly, checking the dipstick frequently to avoid overfilling.
To get an accurate reading when checking the oil level:
The machine should be on a level surface.
The dipstick should be screwed down on Briggs & Stratton engines.
Tip: To avoid confusion, we recommend leaving the Caps on the Fuel and Oil Fills until you are ready to pour either gasoline or oil into the correct Fill.
Note:
Use only SAE 30 High Detergent oil. Other types of oil could cause problems operating your machine. Please refer to your Engine
Owner’s Manual for detailed oil information. You must lift the Bed to access the Oil and Fuel Reservoirs.
Gas Fill
Cap
1.
Place the machine on a level surface and lift the Bed to the fully up position
(Figure 25).
2.
Remove the Oil Dipstick/Fill Cap.
3.
Initially add 14 oz. of SAE 30 High Detergent oil recommended by the
Engine Manufacturer and wait one minute for the oil to settle.
4.
Check the level on 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.
5.
Fill the Fuel Tank to not more than 1/4" from the bottom of the Fill Neck with fresh, unleaded gas. See the Engine Manufacturer’s Owner’s Manual for more information.
Figure 25
Dipstick/Oil Fill
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Connect the Battery Wires (Electric Start Models)
1.
Remove any protective Caps that may be on the Battery Terminals from shipping.
2.
Connect the red wire to the red Terminal and connect the black wire to the black Terminal (Figure 26).
Figure 26
Red
Wire/Terminal
Black
Wire/Terminal
Battery
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Chapter 3: Operating The DR POWERWAGON
It may be helpful to better familiarize yourself with the features of your DR
POWERWAGON by reviewing Figure 2 in Chapter 2 before beginning the steps outlined in this chapter.
Operator
Presence Lever
Before Starting the Engine
1.
Check the oil level every time you use the machine (Figure 25 on page 14).
2.
Check the gas level (Figure 25 on page 14).
3.
Check the tires for proper inflation (Figure 24 on page 14).
4.
Make sure the Dump Latch is secured (Premier and Pro Models) (Figure 2a on page 7).
5.
Set the Parking Brake by squeezing the Brake Lever on the right Handlebar and lift up on the Parking Brake Lock, locking the Lever in place (Figure 27).
Note:
The DR POWERWAGON is equipped with an Operator Presence Control for added safety. The Operator Presence Lever must be depressed whenever the Shift
Lever is in gear, or the Engine will stop
. You may run the Engine without depressing the Operator Presence Lever (Figure 27) only if the Shift Lever is in the "N"
(Neutral) position (Figure 28).
Figure 27
Key Switch
Figure 28
Electric Starting
1.
Move the Shift Lever to the NEUTRAL
N
position (Figure 28).
2.
Move the Throttle Lever to the FAST position.
3.
Turn the Key to the START position. As soon as the Engine starts, release the Key, and it will return to the RUN position.
Brake Lever
Parking
Brake Lock
Shift
Lever
Throttle Control
Recoil
Handle
Manual Recoil Starting
Note:
Manual recoil starting can be used for both Electric-Starting and Manual-
Starting models.
1.
Move the Shift Lever to the NEUTRAL
N
position (Figure 28).
2.
Move the Throttle Lever to the FAST position.
Figure 29
3.
Turn the Key to the RUN position.
4.
Pull the Recoil Handle slowly, until you feel resistance; then pull the Handle with a rapid, full arm stroke to overcome compression and start the Engine (Figure 29). Repeat if necessary. contact us at
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17
Operator
Presence Lever
Figure 30
Key Switch
Figure 31
Figure 32
Operator
Presence Lever
Brake Lever
Operating
The DR POWERWAGON has a three-speed forward transmission and singlespeed reverse. Use the lower gears for slower speeds, heavy loads, or more power, and the higher gears for transport over smooth terrain. Use 1 st
gear with loads over 300 lbs and on slopes. Never use your machine on slopes greater than 15.
1.
After the Engine is started, release the Parking Brake by squeezing and releasing the Brake Lever (Figure 30).
2.
Hold down the Operator Presence Lever.
3.
Move the Shift Lever to the desired gear (Figure 31).
Shift Lever
Always release the Traction Drive Lever when shifting to avoid damaging the gears.
4.
Squeeze the Traction Drive Lever on the right side Handlebar slowly until the machine moves in the desired direction (Figure 32).
Throttle
Control
Squeezing the throttle fast will make the DR POWERWAGON "jump" into motion. Squeeze the throttle slowly and ease the machine into gear.
When engaging reverse, use extra caution. Check your path and footing before engaging the clutch.
Traction Drive
Lever
Stopping
1.
Release the Traction Drive Lever (Figure 32).
2.
Shift to the NEUTRAL
N
position (Figure 31).
3.
Release the Operator Presence Lever (Figure 33).
4.
Set the Parking Brake by squeezing the Parking Brake Lever on the left side
Handlebar and lifting the Parking Brake Lock.
5.
Move the Throttle Control Lever to the SLOW position (Figure 31).
6.
Turn the Key to the STOP position and remove it for safety.
Figure 33
Brake Lever
Parking
Brake Lock
In an emergency situation, releasing the operator presence lever will stop the machine. After the machine stops, follow steps 1, 2 and 4 thru 6 above).
Always set the parking brake when your machine is stopped.
Operating Tips
Avoid abrupt start-ups. Always squeeze the throttle slowly to avoid bucking, or tipping the DR POWERWAGON.
When using reverse, check to see that there are no obstacles behind you.
Practice backing up in an open area with no load in the DR POWERWAGON.
18
D R
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Loading
The recommended maximum load limit for the DR POWERWAGON is 500 lbs (Premier), 700 lbs (Pro) or 800 lbs (Pro-XL).
Never operate on slopes greater than 15°. Placing more weight in the bed may be dangerous to the operator and can permanently damage the unit.
Be careful when transporting heavy loads with your DR POWERWAGON. If the brake is applied suddenly, the load may shift and the wagon may start to tip forward. Brake slowly and try to avoid overloading the wagon.
When loading your DR POWERWAGON keep in mind the bulk and weight of what you will be hauling and the terrain you will be crossing.
Keep the load balanced and secured. Always distribute the load evenly so your DR POWERWAGON will be as stable as possible.
Do not pile material too high. Divide your load and make several lighter trips. Do not pile heavy loads, such as rocks or
gravel, to a height that will make the DR POWERWAGON top-heavy and susceptible to tipping over. st
Be careful going downhill and applying the brake. Shift into 1 gear before going down a slope. Squeeze the brake very slowly to avoid dumping the load.
Slopes and Uneven Terrain
When operating over uneven terrain and slopes, use extreme caution to ensure solid and firm footing. Move slowly if the ground is rough, especially with a full load. Use 1st gear on slopes. Never operate on slopes greater than 15°.
Never operate the DR POWERWAGON on slopes greater than 15 degrees
(Figure 34). This is for safety and proper Engine operation. Doing so could deprive the Engine of oil and cause it to overheat resulting in component
damage.
USE CAUTION: The DR POWERWAGON may become unstable when
moving over ruts, bumps, and other depressions.
When going down a slope, shift into 1 st gear before starting down. Never shift in the middle of a slope. Find as level a spot as possible and set the parking brake before shifting.
On a slope, a heavy load will tend to shift. When using your DR
POWERWAGON, keep in mind that loads tend to shift to the downhill side of the body. Secure your load in the Bed to limit the shifting of the load on slopes. The higher and heavier the load, the greater the chance of tipping over the DR POWERWAGON. Travel up and down slopes. Avoid going across slopes.
Again, be especially careful with full loads. A good rule of thumb: the steeper the hill, the lighter and lower your load should be.
When going downhill, keep a firm grip on the Handlebars and push down slightly. Do not apply the Parking Brake abruptly when going downhill with a heavy load or the DR POWERWAGON may pitch forward onto its front end.
Figure 34
15° Max.
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19
Tailgate
Figure 35
Latch
Unloading the Bed
Dumping – Manually
Note:
For safety reasons, the DR POWERWAGON Bed is designed NOT to dump automatically once you release the Dump Lever. You must pull the Dump Handle up to lift the back of the Bed to cause it to tip forward.
1.
Shift the machine to Neutral and set the Parking Bake.
2.
Remove the Tailgate (Pro Model only) (Figure 35).
3.
Stand at the right rear of the Bed.
4.
Pull up on the Handle of the Dump Lever to dump the load (Figure 36).
5.
After unloading, push the Bed back down into place by hand. Be sure the
Dump Lever latches securely.
Note:
The Bed of the DR POWERWAGON is balanced so you can dump the load with minimal effort. If you are carrying a very heavy load, you may not be able to lift the Bed to dump it when you release the Latch Lever. In this case, you will need to manually remove part of the load from the back of the Bed, until the load is light enough to allow the Bed to tip forward when you lift up on the back of it.
Dump
Lever
Figure 36
Key Switch
Electric Dump System – Pro-XL Model
The Electric Dump System brings new conveniences to the function of your DR
POWERWAGON. We have included some operating hints and precautions.
Please review them carefully.
Operating the Electric Dump
1.
Shift the machine to Neutral and set the Parking Brake.
2.
Remove the Tailgate.
Electric Dump Switch
Figure 37
3.
If the Engine is Off, turn the Key to the RUN position.
4.
Hold the Electric Dump Switch in the upper “DUMP” position, to raise the
Bed to empty it (Figure 37).
5.
Hold Power Dump Switch down in the lower “FLAT” position, to lower the
Bed.
Operating Hints
The Electric Dump System allows the Bed to be stopped and positioned anywhere in the tipping range. Emptying loose
material and depositing solid loads in a more precise way.
The Electric Dump System also makes it possible to distribute loose materials over an area rather than in a concentrated pile for distribution later. With the Bed partially tipped, you can move your DR POWERWAGON in reverse while the material flows from the front of the Bed. This is especially helpful in road maintenance and similar work.
Make certain you are familiar with the terrain where you intend to work and anticipate the effect that load changes in the Dump
Bed might have upon operating factors. Review your Safety
& Operating Instructions Manual carefully for safe procedures.
20
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Chapter 4: Maintaining The DR POWERWAGON
Regular maintenance is the way to ensure the best performance and long life of your machine. Please refer to this manual and the engine manufacturer's owner's manual for maintenance procedures. Service intervals listed in the checklist below supersede those listed in the engine manufacturer's owner's manual.
When performing any maintenance, you must first shut off the engine, set the parking brake, wait five minutes to allow parts to cool and disconnect the spark plug wire, keeping it away from the spark plug.
Regular Maintenance Checklist
P
ROCEDURE
Check Operator Presence Lever
Check Engine Oil Level
Check General Equipment Condition
Check Tire Pressure
Lubricate Caster Wheel Grease Fittings
Clean Air Filter & Pre-cleaner
Change Engine Oil (8.75 Engines Only)
Check Parking Brake Adjustment
Check Belt Tension & Condition
Check Cable Connections
Clean Engine Exterior & Cooling Fins
Replace Spark Plug
Replace Air Filter & Pre-cleaner
B
EFORE
E
ACH
U
SE
E
VERY
25 H
OURS
E
VERY
100 H
OURS
1 st
time 5 hours
Battery Care (For Electric-Starting models)
Proper care can extend the life of a Battery. Follow these recommendations to ensure your Battery’s best performance and long life:
Do not allow the Battery charge to get too low. If the machine is not used, charge the Battery every 4 – 6 weeks. Operate the
Engine for at least 45 minutes to maintain proper Battery charge.
Store an unused Battery in a dry area that does not freeze.
Do not charge an already charged Battery. In theory, you cannot overcharge our Battery with a trickle charger; however, when a
Battery is fully charged and the charger is still on, it generates heat that could be harmful to the Battery. A fully charged Battery will read 12V-13.2V with a voltmeter.
Do not continue to crank the Engine when the Battery charge is low.
Under normal work conditions, the Battery will not need special attention with the addition of the Electric Dump System. If you are operating for extended periods with frequent dumps, it might be best to leave the Engine running during stand still periods to maintain proper charge levels.
Charging the Battery
Operate the engine for at least 45 minutes to maintain proper battery charge. If the battery loses its charge, you will need to use a trickle charger (like the DR Battery Charger) to recharge it. The charger should have an output of 12 volts at no more than 2 amps.
At 1 amp, the Battery may need charging for as long as 48 hours.
At 2 amps, the Battery may need charging for as long as 24 hours.
Note:
Using the Recoil Starter and then running the Engine will not recharge a dead or significantly discharged Battery.
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21
Figure 38
Rear Caster
Brace
Figure 39
Figure 40
Red
Wire/Terminal
Black
Wire/Terminal
To connect a battery charger to your DR POWERWAGON, follow the steps listed below.
1.
Detach the two Battery wires from your Battery (Figure 38).
2.
Attach the red (+) Battery Charger Wire to the red (+) Battery terminal, and the black (-) Battery Charger Wire to the black (-) Battery terminal.
3.
Plug the Battery Charger into an outlet.
Battery
When you are finished charging the Battery, disconnect the Battery Charger from the outlet first, then disconnect the Charger wires from the Battery
Terminals. If the Battery Charger Wires are left connected to the Battery, the
Battery will discharge itself back into the Charger.
Lubrication
Your DR POWERWAGON was lubricated at the Factory. The transaxle is factory sealed and lubricated for life. The operator must provide engine, Caster wheel,
Key Switch and cable lubrication.
CASTER WHEEL LUBRICATION
Supplies Needed:
Grease Gun with #2 Lithium Grease
1.
There are four Grease Fittings for the Caster Wheels: One at the right and left side of the Rear Caster Brace, and one on each Wheel Hub
(Figure 39).
Grease these four Fittings with #2 lithium grease, to keep the Wheel spinning freely, at least every 25 hours of operation.
CABLE LUBRICATION
Supplies Needed:
SAE 30 Oil
#2 Lithium Grease
1.
Using SAE 30 Oil, lubricate the end of the Cables at the Handlebars and
Control Panel (Figure 40) and where the other ends connect to the machine
(Figure 41). Operate the Levers to work lubricant into the Cables.
Figure 41
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ENGINE OIL CHECK AND REPLACE
The Briggs and Stratton 6.75 and 7.25 are “Just Check and Add” Engines. After you have added oil as described in Chapter 2, you are not required to change the Oil in the 6.75 and 7.25 Engines. The 8.75 however will need the Oil changed as scheduled in the
“Regular Maintenance Checklist” at the beginning of this Chapter.
See your Engine Operator manual for more detailed information.
6.75 and 7.25 Engines (Check and Add):
Supplies needed:
SAE 30 High Detergent (HD) Oil (for winter use, use SAE 5W – 30W)
Clean Rag
1.
Lift the Bed to the fully upright position (Figure 42).
2.
Remove the Oil Dipstick/Fill Cap and wipe it off with a clean Rag.
3.
Replace the Oil Dipstick/Fill Cap and screw it in, remove the Dipstick and check the Oil level.
4.
If the level is low, add oil as needed.
5.
Replace the Oil Dipstick/Fill Cap when finished.
Oil Dipstick/Fill Cap
8.75 Engines (Replace Oil):
Tools and Supplies needed:
3/8" Drive Ratchet
SAE 30 High Detergent (HD) Oil (for winter use, use SAE 5W – 30W)
Rag
Approved Oil Drain Pan
Figure 42
1.
Lift the Bed to the fully upright position
(Figure 42).
2.
Place an approved Oil Drain Pan under the Engine Oil Drain Plug at the rear of the machine (Figure 43).
3.
Using a 3/8" Drive Ratchet, remove the Oil Drain Plug from the bottom of the Engine and drain the oil into the Pan.
4.
Replace the Plug and refill the oil to as described in “Adding Oil and
Gasoline” in Chapter 2.
Figure 43
Note:
If you will not be reusing the oil, be sure to use environmentally safe disposal procedures in the disposing of the used oil.
Oil Plug
Alternate Method
Tools and Supplies needed:
SAE 30 High Detergent (HD) Oil (for winter use, use SAE 5W – 30W)
Rag
Liquid Vac Oil Drainer, item #16145 (optional accessory, available at DR Power Equipment)
1.
Lift the Bed to the fully upright position (Figure 42).
2.
Remove the Oil Dipstick/Fill Cap and vacuum the oil from the Engine through the Dipstick Tube using the recommended oil drainer.
3.
Replace the oil as described in “Adding Oil and Gasoline” in Chapter 2. contact us at
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23
Figure 44
Retaining
Ring and
Washer
Figure 45
Skid Plate
Bolts
Removing and Replacing the Belt
Tools needed:
Two Jack Stands
Flat Head Screwdriver
9/16" Socket with Ratchet and Extension
Pliers
Jack Stands
Skid Plate
Wheel
Use only DR belts on your machine. They have been thoroughly tested and proven for many hours of use.
1.
Position the machine on a level surface and support the front of the Frame with Jack Stands to lift the Wheels off the ground (Figure 44).
Note:
Ensure that the Jack Stands are not touching the Wheels.
2.
Remove the Retaining Ring and Washer of both Wheels with a Flat Head
Screwdriver and remove the Wheels (Figure 45).
3.
Tip the Bed forward for better access.
4.
Remove the twelve (six per side) Skid Plate Bolts at the sides of the Frame using a 9/16" Socket with Ratchet and Extension (Figure 46).
5.
Remove the Skid Plate from the machine
.
6.
Remove the Belt from the Engine, Idler/Tensioner and Transaxle Pulleys
(Figure 47)
.
7.
Install the new Belt on the Engine and Transaxle Pulleys.
8.
Route the Belt between the Idler/Tensioner Pulleys as shown.
9.
Reinstall the Skid Plate making sure that the Belt is on the inside of all Belt
Guides (Figure 48).
10.
Reinstall the Wheels, making sure that the key is in position on the Transaxle shafts.
Figure 46
Belt
Belt
Engine
Pulley
Figure 47
Idler/Tensioner
Pulleys
Transaxle
Pulley
24
D R
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Figure 48
Belt guides
Removing and Replacing the Front Wheels
Tools needed:
Blade Screwdriver
Eye protection
Jack Stands
Pliers
Frame
Tubes
1.
Block the machine up off the ground so that the Front Wheels spin freely
(Figure 49).
2.
Pry off the Wheel Lock Ring with a Screwdriver (Figure 50). Remove the
Washer and slide the Wheel off the Axle. Check the Axle to ensure the Key stayed in the Axle.
3.
To replace the Wheel, align the groove in the Wheel Hub to the Key and slide the Wheel onto the Axle.
4.
Reinstall the Washer and Wheel Retaining Ring.
Figure 49
Tip: Pliers may work better to seat the Retaining Ring.
Checking and Adjusting the Brakes
Retaining
Ring and
Washer
The Brakes are adjusted at the Factory but may need adjustment over time due to Brake Pads wearing down. The Brakes can be adjusted at the Brake Arm
Adjustment Nut as well as the Brake Cable Jam Nuts. This section explains both methods of adjusting your Brakes.
Figure 50
Tools needed:
Two 1/2" Wrenches
CHECKING THE BRAKES:
Brake
Arm
Brake Arm
Adjustment
Bolt
1.
With the machine on a level surface, set the Parking Brake.
2.
Move the Shift Lever to the NEUTRAL
N
position.
3.
Test the Brakes by trying to roll the machine. It should not move in either direction with the Parking Brake set. If it does move, continue to “BRAKE
ARM ADJUSTMENT”. If it doesn’t move, your Brakes are properly adjusted.
BRAKE ARM ADJUSTMENT:
If this adjustment method doesn’t make a difference after a couple of adjustments, continue to “BRAKE CABLE ADJUSTMENT”.
Brake Cable
Adjustment Jam Nuts – Inner - Outer
Figure 51
Jack
Stands
Wheel
1.
Turn the Adjustment Nut on the Brake Arm
1/4 turn clockwise with a 1/2" Wrench to tighten the Brakes (Figure 51).
2.
Test the Brake as described “CHECKING THE BRAKES” above. Repeat the adjustment as needed until the Brake works properly.
BRAKE CABLE ADJUSTMENT:
If this adjustment method doesn’t improve braking after a couple of adjustments, continue to “CHANGING THE BRAKE PADS”.
1.
Turn the inside Jam Nut a full turn away from the Brake Arm (Figure 51).
2.
Turn the outside Jam Nut against the Brake Arm and inside Jam Nut.
3.
Test the Brakes as described “CHECKING THE BRAKES” above. Repeat the adjustment as needed until the Brake works properly. contact us at
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25
PARKING BRAKE ADJUSTMENT:
You must ensure the Parking Brake Lock works properly whenever the Brakes are adjusted. If the Brakes are adjusted too tight the
Lever will not squeeze tight enough to the Handle and the lock will not engage or it will engage and is extremely difficult to disengage.
Perform the previous BRAKE CABLE ADJUSTMENT and/or the BRAKE ARM ADJUSTMENT in the opposite direction than described to loosen the Brake Cable.
Note:
Turn the Adjustment Nuts only 1/4 turn at a time, and then test the Parking Brake Lock to see if the adjustment worked.
Cable
Bracket
Cable
Bracket
Bolt
Figure 52
Bracket
Bolt
Figure 53
Brake Disc
Backing Plate
Caliper Bolt
(Short)
Brake
Pad
Spacer
Caliper Bolt
(short)
Caliper Bolt
(long)
Brake Pad
Actuator Pins
Caliper
Bolt
(long)
Changing the Parking Brake Pads
Note:
If your DR POWERWAGON rolls on slopes when the Parking Brake is set, and you have tried adjusting the Brakes, the Brake Pads may need replacement.
Tools and Supplies needed:
3/8" Socket with Ratchet and Extension
1/2" Socket with Ratchet and Extension
Lithium Grease
Clean Mat or container for loose parts
Note:
You may want to remove the Wheel to provide easier access to the Brake
Caliper area. See “Removing and Replacing the Front Wheels” in this Chapter.
1.
Find a clean level area to work. The Parking Brake should NOT be engaged.
Chock the Wheels so the machine cannot move.
2.
Locate the Brake Caliper at the right/front of the machine
(Figure 52).
3.
Remove the Cable Bracket Bolt using a 1/2" Socket with a Ratchet and
Extension.
4.
Remove the long Caliper Bolt with a 3/8" Wrench and remove the Spacer from the Transaxle.
5.
Remove the short Caliper Bolt with a 3/8" Wrench and remove the Caliper from the Transaxle.
Note:
The inside of the Caliper contains four small parts: the Brake Pad, the
Backing Plate, and two small Actuator Pins (Figure 53). As you let the Caliper hang from the Brake Cable, keep track of these parts as they will likely fall out. Clean away any debris from these parts and the inside of the Caliper.
6.
Pull the Brake Disc off the splined Shaft and remove the Brake Pad (Figure
54
).
7.
Insert a new Brake Pad into the cavity and hold in place as you reinstall the
Brake Disc.
8.
Lightly grease the Actuator Pins with Lithium Grease and insert the Pins into the Caliper (Figure 53).
9.
Insert the Backing Plate with new Brake Pad and position the Caliper onto the Transaxle.
10.
Secure the Caliper and Cable Bracket in the reverse order of disassembly.
Note:
After new Brake Pads have been installed you will need to perform the
“Checking and Adjusting the Brakes” procedures to compensate for the thicker Pads.
Figure 54
26
D R
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Adjusting the Traction Drive Cable
When properly adjusted, tension on the Traction Drive Lever should increase when the Lever is about parallel to (almost touching) the Handlebar Grip. If it does not, perform the following steps.
1.
Locate the In-Line Adjuster on the Traction Drive Cable along the right
Handlebar (Figure 55).
2.
Rotate the center portion clockwise while holding the ends stationary to expand the In-Line Adjuster and remove slack from the cable.
Adjusting the Shift Cables
If there is a lot of “play” in the Wheel Speed Lever or if the lever is no longer aligned with the Wheel Speed Label, you may need to adjust the Shift Cables as follows.
Tools needed:
Two 13mm Wrenches
1.
Locate the Shift Cable Adjustment Nuts on the Shift Lever end of the cable
(Figure 56)
.
2.
Loosen the top Cable Jam Nut one of the cables using two 13mm
Wrenches.
3.
Pull down slightly on the cable Sheathing, just enough to pull out the slack in the Cable and then tighten the bottom Cable Adjustment Nut against the
Bracket. Retighten the top Nut against the Bracket and bottom Nut using two 13mm Wrenches. You may need to tension one cable while loosening the other to realign the Lever.
Note:
Do not over tighten the cable. It will create a spongy feel in the shift lever if it is too tight.
Figure 55
Figure 56
Pro-XL Dump Actuator Maintenance
For the Electric Dump System, the dump actuator is a sealed unit that does not need servicing under normal use.
Tighten
Traction
Drive Cable
In-Line Adjuster
Shift
Cables
Bracket
Top Nut
Bottom Nut
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28
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Chapter 5: Troubleshooting
Most problems are easy to fix. Consult the Troubleshooting Table below for common problems and their solutions. If you continue to experience problems, contact us at www.DRpower.com or call toll-free 1-800-DR-OWNER (376-9637) for support.
When performing any maintenance, you must first shut off the engine, set the parking brake, wait five minutes to allow parts to cool and disconnect the spark plug wire, keeping it away from the spark plug.
Troubleshooting Table
S
YMPTOM
Recoil will not pull out or is difficult to pull.
The Engine will not start manually.
(Please refer to the
Engine Owner’s
Manual for Enginespecific procedures.)
The Engine will not start using Electric-
Start.
(Please refer to the
Engine Owner’s
Manual for Enginespecific procedures.)
Engine smokes.
P
OSSIBLE
C
AUSE
Check the Engine oil level; the Engine may be seized.
There may be an oil compression lock in the cylinder. Take out the Spark Plug; hold a rag over the
Spark Plug hole and pull the Recoil Cord several times to blow out any oil in the cylinder. Wipe off the Spark Plug and reinstall it.
Check that the Key is in the RUN Position.
Check that the Spark Plug wire is attached.
Check the Operator Presence Switch connection beneath the Panel at the Key Switch.
Check the Operator Presence Switch connection at the Engine.
Check the oil and gas level. See “Adding Oil and Gasoline” on page 14.
The gas may be old, change it. Use a fuel stabilizer if you keep gas longer than one month.
Check the Throttle adjustment and travel.
The Spark Plug may be dirty or cracked, change it.
If the Spark Plug is oily, leave it out, hold a rag over the Plug hole and pull the Recoil cord several times to blow out any oil in the cylinder, then wipe off the Plug and reinsert it.
The Air Filter may be dirty, change it following the procedure in the Engine Owner’s Manual.
If your Engine still won’t start, contact us at www.DRpower.com.
Check all the items under the section “Electric-Starting” on page 17.
Check the previous section (The Engine will not start manually.) for possible causes.
Check the wire connections—especially the ground connection, the large black wire coming from the
Battery, where it connects to the Engine.
The Battery may not be charged. Check the voltage yourself or at a Service Station. If it is low, charge it with a 12-volt, 1 to 2-amp trickle charger. If you do not use your machine for at least 45 minutes at a time, the Battery may need to be periodically charged. See the “Battery Care” section on page 21.
If the Battery is charged and your DR POWERWAGON still will not start, contact us at www.DRpower.com.
Check the oil level and adjust as needed.
You may be operating the machine on too great an incline. See the “Slopes and Uneven Terrain” section on page 19.
Check the Air Filter and clean or replace if needed.
You may be using the wrong oil—too light for the temperature. Refer to the Engine Owner’s Manual for detailed information.
Clean the Engine cooling fins and the carburetor housing if they are dirty.
If the Engine still smokes, contact us at www.DRpower.com. contact us at
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29
When performing any maintenance, you must first shut off the engine, set the parking brake, wait five (5) minutes to allow parts to cool and disconnect the spark plug wire, keeping it away from the spark plug.
Troubleshooting Table (Continued)
S
YMPTOM
The Engine lacks power or is not running smoothly.
(Please refer to the Engine Owner’s
Manual for Engine-specific procedures.)
P
OSSIBLE
C
AUSE
Check the Throttle travel and adjustment.
The Air Filter may be dirty, change it following the procedure in the Engine Owner’s Manual.
The Spark Plug may be dirty or cracked, change it.
If the Spark Plug is oily, leave it out, hold a rag over the Plug hole and pull the Recoil cord several times to blow out any oil in the cylinder, then wipe off the Plug and reinsert it.
The gas may be old, change it. Use a fuel stabilizer if you keep gas longer than one month.
The Engine may not have the right amount of clean oil. If it is dirty, change it (8.75 Engines only) following the procedure on page 23.
If the Engine still lacks power, contact us at www.DRpower.com.
The Shift Lever may need adjusting. See page 27.
Machine is hard to get into
Reverse.
Wheels pulling left or right.
Check the tire(s) pressure. See page 14.
Machine lacks traction.
The load may be uneven in the Bed. The more weight over the Wheels the better the traction.
Try a lower gear.
If you are working on rough terrain you may want to consider the Tire Chain Kit. Call 1-800-DR-
OWNER (376-9637) for information.
The Wheels will not turn.
Make sure that the DR POWERWAGON is in gear.
Check that the Parking Brake is off.
The Drive Belt may be loose or off the Pulley. See page 24.
The Drive Belt may be on the wrong side of the Pulley. See page 24.
If the Wheels still will not turn, call 1-800-DR-OWNER (376-9637) for assistance.
The Electric Dump System is not responding.
There is a Fuse under the Control Panel. Check the Fuse and replace if needed.
Check for loose electrical connections.
Check to be sure the Key Switch is in the RUN position to operate the Electric Dump System.
See page 20.
Check the Battery charge. If the Key activates the Starter, the Battery is sufficiently charged. If it does not start the Engine, charge the Battery and repeat.
If the Electric Dump System still will not respond, call 1-800-DR-OWNER (376-9637) for assistance.
The Dump Bed stops with the Switch Button depressed.
Release the Switch and try the opposite direction. If the Dump Bed moves, check the area beneath the Dump Bed for obstructions.
If the Dump Bed does not move in the opposite direction, check the Battery and connections as above.
If the Dump Bed still stops, call 1-800-DR-OWNER (376-9637) for assistance.
30
D R
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POWERWAGON
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31
Chapter 6: Parts Lists and Schematic Diagrams
Parts List - Handlebar/Controls Assembly
Note:
Part numbers listed are available through DR Power Equipment. Not all parts appear on all diagrams.
Ref# Part# Description Ref# Part# Description
1 37919 Brace, Rear, Casters
3 38541 Wheel, 11 - 4 X 5, Rib, 3/4 Bb X 5" Sym
4 13447 Battery, 9ah
8 18069 Lever, Op Presence W/ Harness
9
10
30297
39116
Lever, Brake, W/O Hardware
Lever, Cable, Black, Traction Drive, With
Labels
11 38515 Cable,
12 37051 Collar, Lever, 1", Threaded
13 16496 Grip,
14 38577 Control Panel, With Labels
15 38576 Control Top Plate, With Labels
(Premier and Pro Models)
16 16520
22223
17 19003
18 15131
(Pro-XL Model)
Switch, Snap-In, M/S
Switch, Snap-In, E/S
Plug, Plastic, 1/2" Hole
Plug, Hour Meter Hole, 2" X 1-1/4"
19 35107 Mount, Shift
20 35106 Lever,
21 15036 Knob, PTO Clutch Cable
22 37939 Cable,
23 38546 Cable, Throttle, 40" L
24 38549 Wire Actuator (Pro-XL Only)
25
26
27
28
29
30
31
33333
38596
33332
34324
33348
35290
11173
Nut, Nylon Lock, Flanged, 3/8-16
Bolt, Hex, Flange, 3/8-16 X 1-3/4", GR5,
ZP
Nut, Nylon Lock, Flanged, 5/16-18
Bolt, HCS, 3/4-10 X 7", ZP
Bolt, Hex, Flange, 3/8-16 X 2.5"
Bolt Shoulder, 1/2" X 5/8"L, 3/8-16
Bolt, HCS, Serrated Flange 5/16-18 X
.50"
Bolt, Carr, 5/16-18 X 1.75", GR5, ZP 32 35033
33 31306
34 17923
35 15049
Bolt, HCS, 1/4-20 X 2-1/4", GR5, ZP
Screw, SHCS M6 X 25mm
Screw 8-32 X 1/2"
36 33338
37 33331
Nut, Nylon Lock, Flanged, 3/4-10
Nut, Nylon Lock, Flanged, 1/4-20
38 12376 Bushing 1.0"OD
39 10189 Grease Fitting, 1/4-28, Straight
40 18655
41 15720
42 38553
43 38554
Pin, Cotter, 3/16" X 2"
Key, Ignition Switch
Label, Throttle, Wheel Speed
Label, Operator Instructions
44 38555
45 38552
46 37055
47 38557
Label, Power Dump (Pro-XL Only)
Label, Warning & QR Code
Label, Traction Drive
Label, Branding, Console
Not Illustrated
38548
38550
38583
Wire Harness, ES
Wire Harness, M/S
Plug, Control Panel, Actuator Switch
Cutout (Premier and Pro Models Only)
32
D R
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POWERWAGON
Schematic - Handlebar/Controls Assembly
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33
6
7
3
4
1
2
Parts List - Drive Assembly
Note:
Part numbers listed are available through DR Power Equipment. Not all parts appear on all diagrams.
Ref# Part# Description Ref# Part# Description
8
37913
37914
37909
38567
37389
35302
11114
Tube, Frame, Right
Tube, Frame, Left
Bracket, Angle, Skid Plate
Plug, 1-1/2" OD, 12 GA Tube
Transaxle, 3 Spd, W/ Brake
Wheel Assembly, Snow Hog, 4.8-8,
Keyed Hub
Pulley, V, 7" OD 4l/A Belt
10 37929 Bushing,
11 11307
12 14409
Pulley, Flat Idler, 2-1/4"
Pulley, V-Belt, 2.625" OD, Idler
13 35261 Spring,
14 38545 Belt,
15 37915
16 37900
17 38578
38579
38580
18 38547
19 33333
20 33332
21 34326
22 39086
Bushing, Belt Guide
Pulley, 2.75" OD, 7/8" Shaft, A Belt
Engine, B&S, 8.75 Pro, E/S, With Labels
Engine B&S 7.25 EXI ES, W/Labels
Engine B&S 6.75 EXI M/S, W/Labels
Cable, Brake, 64" L
Nut, Nylon Lock, Flanged, 3/8-16
Nut, Nylon Lock, Flanged, 5/16-18
Bolt, Hex, Flange, Grade 8, 3/8-16 X 3"
Bolt, Hex, Flange, 3/8-16 X 2-1/4", GR8,
ZP
23
24
34407
35281
Bolt, Hex, Flange, 3/8-16 X 1.5", GR5, ZP
Bolt, Hex, Flange, Tri Lobe, 3/8-16 X
3/4", GR5 ZP
25 11155 Bolt, 3/8-24 X .75", GR.2, ZP
26
27
38592
11173
Bolt, Carr, 3/8-16 X .75", GR5, ZP
Bolt, HCS, Serrated Flange 5/16-18 X
.50"
Bolt, HCS, 5/16-18 X 1-3/4", GR5, ZP 28 15045
29 11150
30 38591
Bolt, SHCS, 1/4-18 X 3/4", Black Oxide
Bolt, Carr, 1/4-20 X 2", GR5, ZP
31 38945 Washer, Flat,.75" X 1.125" X .012"
32 11238 Washer, 1/4"
33 11250
34 11069
35 33331
36 11124
Washer Lock 1/4" External Tooth
Nut, Hex, 5/16-18, GR2, ZP
Nut, Nylon Lock, Flanged, 1/4-20
Snap Ring, External, 5/8"
37 11126
38 10119
Ring, Retaining, 3/4" E-Clip
Key, Square, 3/16" X 2"
39 37911 Plate,
40 37912 Mount,
41 37930 Bracket,
Safety Labels
34
D R
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POWERWAGON
Schematic - Drive Assembly
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35
3
4
5
6
8
9
Parts List – Premier Bed and Frame Assembly
Note:
Part numbers listed are available through DR Power Equipment. Not all parts appear on all diagrams.
Ref# Part# Description Ref# Part# Description
39094
37918
37927
11108
38572
38540
10 33805
11 33335
12 33353
13 33333
14 33332
15 38598
16 39085
Premier Poly Bed, With Labels
Tube, Support, Poly Bed
Brace, Poly Bed
Plug, 1" X 1" OD, 16GA tube
Handle, Dump, With Labels
Spring, Torsion, 360 Deg, .063" Wire,
.798" OD
Spacer, .327" ID X .51" OD X 2.69"
Nut, Nylon Lock, Flanged, 1/2-13
Bolt, Hex, Flange, 1/2-13 X 4", GR5
Nut, Nylon Lock, Flanged, 3/8-16
Nut, Nylon Lock, Flanged, 5/16-18
Bolt, Hex, Flange, 5/16-18 X 2-1/2", GR8,
ZP
Bolt, Hex, Flange, 5/16-18 X 3", GR8, ZP
17 10940
19 39086
Bushing .395" ID X .500" OD
18 10877 Arm,
Bolt, Hex, Flange, 3/8-16 X 2-1/4", GR8,
ZP
20
21
38593
38599
Bolt, Hex, Flange, 5/16-18 X 4", GR8, ZP
Bolt, Hex, Flange, 5/16-18 X 1-3/4", GR5,
ZP
Bolt, HCS, 5/16-18 X 5-1/2", GR5, ZP 22 38597
23 35033
24 38594
25 10668
26 33331
Bolt, Carr, 5/16-18 X 1.75", GR5, ZP
Bolt, FHCS, 1/4-20 X .75", GR5, ZP
Nut, Lock, Serrated Flange, 5/16-18
Nut, Nylon Lock, Flanged, 1/4-20
27 37910 Bracket, Transaxle
28 37928
29 38562
30 38563
31 15342
Bracket, Bed Rest, Left
Bracket, Bed Rest, Right
Label, Branding, Bed
Label, Dump Lever
36
D R
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POWERWAGON
Schematic – Premier Bed and Frame Assembly
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37
2
3
Parts List – Pro and Pro-XL Bed Assembly
Note:
Part numbers listed are available through DR Power Equipment. Not all parts appear on all diagrams.
Ref# Part# Description Ref# Part# Description
5
11108
37924
38574
9 33335
10 37936
11 37937
12 33333
13 38596
14 39084
15 33332
16 38598
17 39085
Plug, 1" X 1" OD, 16GA tube
Tube, Support, Cartbed
Cart Bed, With Labels
Nut, Nylon Lock, Flanged, 1/2-13
Bracket, Actuator, Dump Arm
Linear Actuator, 12 V, 200 mm Stroke
Nut, Nylon Lock, Flanged, 3/8-16
Bolt, Hex, Flange, 3/8-16 X 1-3/4", GR5,
ZP
Bolt, Hex, Flange, 1/2-13 X 1-1/2", GR5,
ZP
Nut, Nylon Lock, Flanged, 5/16-18
Bolt, Hex, Flange, 5/16-18 X 2-1/2", GR8,
ZP
Bolt, Hex, Flange, 5/16-18 X 3", GR8, ZP
18 10940
20 39086
Bushing .395" ID X .500" OD
19 10877 Arm,
Bolt, Hex, Flange, 3/8-16 X 2-1/4", GR8,
ZP
21 38593
22 38599
Bolt, Hex, Flange, 5/16-18 X 4", GR8, ZP
Bolt, Hex, Flange, 5/16-18 X 1-3/4", GR5,
ZP
Bolt, Carr, 5/16-18 X 3", GR5, ZP 23 35034
24 38594
25 39083
Bolt, FHCS, 1/4-20 X .75", GR5, ZP
Screw, Plastic Thread Forming, Pan
Head, # 2 Philips, #8-18 X 1/2", Stl, ZP
26 10668
27 33331
Nut, Lock, Serrated Flange, 5/16-18
Nut, Nylon Lock, Flanged, 1/4-20
28 37910 Bracket, Transaxle
29 37928 Bracket, Bed Rest, Left
30 38562 Bracket, Bed Rest, Right
31 38587 Plate,
32 38588 Rib,
33 34139
34 38563
Label, DR Logo, 4", 4 Color
Label, Branding, Bed
38
D R
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POWERWAGON
Schematic – Pro and Pro-XL Bed Assembly
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39
Parts List – Flatbed Assembly
Note:
Part numbers listed are available through DR Power Equipment. Not all parts appear on all diagrams.
Ref# Part# Description Ref# Part# Description
4 38540 Spring, Torsion, 360 Deg, .063 Wire, .798
OD
7
8
9
33353
33335
39090
10 39087
11 15342
Bolt, Hex, Flange, 1/2-13 X 4", GR5
Nut, Nylon Lock, Flanged, 1/2-13
Screw, Round Head, Self Tapping, #10 X
5/8", ZP
Washer, Fender, #10 X 1.0" X .050", ZP
Label, Dump Lever
6 11108 Plug, 1" X 1" OD, 16ga Tube
40
D R
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POWERWAGON
Schematic – Flatbed Assembly
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42
D R
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POWERWAGON
D R
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POWERWAGON
2-Year Limited Warranty
Terms and Conditions
The DR
POWERWAGON is warranted for two (2) years against defects in materials or workmanship when put to ordinary and normal consumer use; ninety (90) days for any other use.
For the purposes of all the above warranties, “ordinary and normal consumer use” refers to non-commercial residential use and does not include misuse, accidents or damage due to inadequate maintenance.
DR Power Equipment certifies that the DR
POWERWAGON is fit for ordinary purposes for which a product of this type is used. DR Power Equipment however, limits the implied warranties of merchantability and fitness in duration to a period of two (2) years in consumer use, ninety (90) days for any other use.
The 2-Year Limited Warranty on the DR
POWERWAGON starts on the date the machine ships from our factory. The
2-Year Limited Warranty is applicable only to the original owner.
The warranty holder is responsible for the performance of the required maintenance as defined by the manufacturer's owner's manuals. The warranty holder is responsible for replacement of normally wearing parts such as the Drive
Belts, Battery, Brake Pads, Filters, and Spark Plug. Accessories to the machine are not covered by this warranty.
During the warranty period, the warranty holder is responsible for the machine transportation charges, if required.
During the warranty period, warranty parts will be shipped by standard method at no charge to the warranty holder.
Expedited shipping of warranty parts is the responsibility of the warranty holder.
SOME STATES DO NOT ALLOW LIMITATIONS ON THE LENGTH OF IMPLIED WARRANTIES, SO THE ABOVE
LIMITATIONS MAY NOT APPLY TO YOU.
DR Power Equipment shall not be liable under any circumstances for any incidental or consequential damages or expenses of any kind, including, but not limited to, cost of equipment rentals, loss of profit, or cost of hiring services to perform tasks normally performed by the DR
POWERWAGON.
SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL
DAMAGES, SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU.
THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU ALSO HAVE OTHER RIGHTS, WHICH VARY
FROM STATE TO STATE.
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43
Daily Checklist for the DR POWERWAGON
When performing any maintenance, you must first shut off the engine, set the parking brake, wait five minutes to allow parts to cool and disconnect the spark plug wire, keeping it away from the spark plug.
To help maintain your DR POWERWAGON for optimum performance, we recommend you follow this checklist each time you use your machine.
[ ] OIL: With the machine on a level surface, remove the Oil Fill Cap and check the oil level. Fill the reservoir according to the Dipstick with SAE30 HD motor oil.
[ ] GAS: Fill the Fuel Tank with fresh, unleaded gasoline.
[ ] ENGINE: It is very important to keep the Engine clean. Remove grass and other debris from the Engine Cooling Fins and Debris Guard.
A dirty Engine retains heat and can cause damage to internal Engine components.
[ ] BELT: Check the Belt for wear.
[ ] AIR FILTER: A clean Air Filter will mean a much easier starting and cooler running Engine. Please refer to your Engine Owner's Manual for instructions on cleaning the Air Filter.
[ ] TIRES: Check the Tires for wear and proper inflation.
End of Season and Storage
When performing any maintenance, you must first shut off the engine, set the parking brake, wait five minutes to allow parts to cool and disconnect the spark plug wire, keeping it away from the spark plug.
Note:
Please refer to the Engine Owner's Manual for Engine-specific procedures.
Change the oil
(8.75 Engines only)
; this will help to eliminate sludge and acids in the Engine. For winter use, use SAE 5W – 30W.
If your DR POWERWAGON will be idle for more than 30 days, we recommend using a gas stabilizer. This will prevent sediment from gumming up the carburetor. If there is dirt or moisture in the gas or tank, remove it by draining the tank. Completely fill the tank with fresh, unleaded gas and add the appropriate amount of stabilizer or gasoline additive. Run the Engine for a short time to allow the additive to circulate.
Remove the Spark Plug and pour about 1 ounce of motor oil into the cylinder hole. Replace the Plug and pull the Recoil Starter Rope until you feel strong resistance. This will coat the piston and seat the valves to prevent moisture buildup.
Clean and/or replace the Air Filter(s).
Clean dirt and debris from the cylinder head cooling fins, carburetor linkage, blower housing, rotating screen, and muffler area of the
Engine.
Check to make sure the operator controls are moving freely. Lubricate the Throttle Lever Cable, Parking Brake Cable and Traction
Control cable with SAE 30 Oil if necessary. See page 22.
Electric starting models: Remove the Battery and keep it in a cool, dry place when the DR POWERWAGON is in storage. We suggest charging the Battery once a month while the DR is stored, and again before you are ready to start the new season. This will help the
Battery maintain its charge all season. See page 21.
DR
®
Power Equipment
7 5 M E I G S R O A D , P . O . B O X 2 5 , V E R G E N N E S , V E R M O N T 0 5 4 9 1
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