Chapter 2: Setting Up The DR POWERWAGON. DR PRO-XL, Premier, PRO

DR PRO-XL is a high-performance machine designed to make tough jobs easier. Its powerful engine and rugged construction allow it to handle a variety of tasks, from hauling heavy loads to clearing snow. With its versatile design, the DR PRO-XL is a valuable tool for any homeowner or professional. Here are some of the things you can do with your DR PRO-XL:

Haul heavy loads with ease
Clear snow quickly and efficiently
Cultivate your garden
Grade your driveway or yard
Transport materials around your property

The DR PRO-XL is built to last, with a durable steel frame and high-quality components. It's also easy to operate and maintain, making it a great choice for anyone looking for a reliable and versatile 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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POWERWAGON

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

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

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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Figure 4

Figure 5

Bolts and

Locknuts

Figure 6

Dump

Handle

Figure 7

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POWERWAGON

Handlebar

Assembly

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.

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.

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.

Position the Dump Handle at the right rear corner of the Bed where the

Mounting Bracket is located (Figure 7).

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).

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.

Rotate the remaining end of the Spring and secure it under the Spring Tab

(Figure 9).

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

Place the Bed on the Power Wagon with the Dump Arms inside the Frame at the front of the Bed Assembly (Figures 12).

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

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).

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

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

Place the Bed Assembly at the front of the machine with the Tailgate end resting on the ground (Figure 16).

Move the Bed Assembly onto the Dump Arms and rotate the Bed back and onto the Dump Arms.

PRO MODEL WITH HAND DUMP

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

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

Actuator

Bracket

Actuator

Dump

Arm

Mounting Hole

(Facing Actuator)

Figure 18

Figure 17

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POWERWAGON

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).

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.

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.

Remove the Plastic Protectors (if present) from the end of the actuator

(Figure 21).

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

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

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.

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

Remove the Valve Stem Protective Cap and check the tire pressure with a tire pressure gauge (Figure 24).

If the pressure is too low, add air through the Valve Stem with an air hose.

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

Place the machine on a level surface and lift the Bed to the fully up position

(Figure 25).

Remove the Oil Dipstick/Fill Cap.

Initially add 14 oz. of SAE 30 High Detergent oil recommended by the

Engine Manufacturer and wait one minute for the oil to settle.

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.

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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POWERWAGON

Connect the Battery Wires (Electric Start Models)

Remove any protective Caps that may be on the Battery Terminals from shipping.

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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POWERWAGON

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Key features

Powerful engine for heavy-duty tasks
Rugged construction for durability
Versatile design for a variety of tasks
Easy to operate and maintain

Frequently asked questions

The maximum load capacity of the DR PRO-XL is 800 lbs.

Yes, the DR PRO-XL can be used to clear snow with the optional snow blade attachment.

The DR PRO-XL requires regular maintenance, including oil changes, filter changes, and lubrication. Please refer to the owner's manual for specific maintenance instructions.