® ™ DR POWERWAGON Safety & Operating Instructions Model: PRO Please read through these Safety & Operating Instructions and the separate Engine Manufacturer's Owner's Manual to become familiar with the basic features of the DR® POWERWAGON™ before operating it.
And congratulations on your purchase of a new DR® POWERWAGON™! We have done our utmost to ensure your DR® POWERWAGON™ will be one of the most troublefree and satisfying pieces of equipment you have ever owned. Please let us know of any questions or problems you may have. We want to answer or correct them as quickly as possible. (When you do call or write, please have your serial number and/or order number handy—it will speed things up!) We also hope to hear from you on how much you like your new helper.
Safety Information We want you to enjoy years of productive use from your DR® POWERWAGON™. We don't want you to get injured, so please take a few moments to read the following guidelines for safely operating your new machine. Dress Appropriately • Wear shoes with non-slip treads when using your DR® POWERWAGON™. If you have safety shoes, we recommend you wear them. Do not use the machine while barefoot or wearing open sandals.
• When shifting to reverse, be careful to avoid tipping as the swivel wheel changes direction. • Do not rev the engine. Excessive speed or tampering with the governor can be dangerous. Operate the engine at the slowest speed that is satisfactory to do the job. • While using the DR® POWERWAGON™, cultivate the habit of not hurrying or taking things for granted. When in doubt about the equipment or surroundings, stop the machine and take time to look things over.
Table of Contents DRESS APPROPRIATELY ............................................................................................................................................ 3 PREPARATION ........................................................................................................................................................... 3 OPERATING THE MACHINE SAFELY ..........................................................................................................................
Safety/Operation Labels • Always replace damaged or missing safety/operation labels immediately.
Assembly & Set Up The DR® POWERWAGON™ is shipped almost completely assembled. Please read the following instructions to complete assembly. Parts Bag Contents: • (2) 5/16" x 1-1/2" bolts & lock nuts for the handlebars • (1) 1/4" x 1-1/4" bolt & lock nut for the shift lever coupling • (3) cable ties for the cable assembly WARNING! 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.
Connect the Shift Lever Coupling Tools Needed: • (2) 7/16" open-end, box or socket wrenches 1. Position the shift lever so the indicator is pointing to neutral on the control panel. 2. Insert the lower end of the shift rod into the shift coupling. Line up the holes on the shift rod and the shift coupling. Insert the bolt, mount the nut and tighten (Figure 3). 3. Sometimes it may be necessary to pull downward on the control panel to make the holes line up in the shift rod and coupler.
Controls & Features Figure 5 POWERWAGON™ Safety & Operating Instructions 9
Starting & Operating Before Starting • Set the parking brake. The hand brake on the right handlebar is equipped with a lever to lock it in the ON position. When the hand brake is locked ON, it functions as the parking brake (Figure 6). Check the oil level every time you use the machine Check the gas level. Check the tires for proper inflation. Make sure the dump latch is secured. • • • • Electric-Starting Figure 6 1. Shift the transmission to "N" neutral. 2.
Stopping 1. 2. 3. 4. Release the throttle. Shift to "N" neutral. Set the parking brake by squeezing the brake lever on the right handlebar and setting the lock. Turn the key to the OFF position. Remove the key to prevent misuse.
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™. • When using reverse with the Sulky attached, proceed slowly so you don't jackknife the POWERWAGON™ and the Sulky. Loading WARNING! The recommended maximum load limit for the DR® POWERWAGON™ PRO model is 800 lbs.
• 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 brake abruptly when going downhill with a heavy load or the DR® POWERWAGON™ may pitch forward onto its front end. Dumping Note: For safety reasons, the DR® POWERWAGON™ bed is designed NOT to dump automatically once the dump lever is released.
General Maintenance *** For Engine Maintenance, Please Refer to the Engine Manufacturer's Owner's Manual. *** Regular Maintenance Check List 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 supercede those listed in the engine manufacturer's owner's manual.
Battery Care Electric-Starting Models Proper care can lengthen 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, the battery should be charged every 4 – 6 weeks. • Store an unused battery in a dry area that does not freeze. • Do not charge an already charged battery.
Changing the Oil Change the oil as directed by your engine manufacturer's owner's manual. Tools & Supplies Needed: • 3/8" ratchet and extension • 3/4" socket • adjustable wrench • SAE30 HD motor oil • suitable container for old oil • rag or cloth ! WARNING: Always disconnect the spark plug wire before servicing your machine. 1. Remove the oil drain plug from the bottom of the engine (Figure 10) and drain the oil. 2. Replace the plug and refill the oil to the level indicated on the dipstick.
Lubrication Supplies Needed: • #2 lithium grease • FLUID FILM® or similar lubricant ! WARNING: Always disconnect the spark plug wire before servicing your machine. 1. There are two grease fittings on the swivel wheel: one at the top front of the wheel bracket (Figure 13), and one toward the center of the wheel (Figure 14). Occasionally grease these two fittings with #2 lithium grease to keep the wheel spinning freely. 2.
To Remove the Front Wheels Tool Needed: • Flat-head screwdriver ! WARNING: Always disconnect the spark plug wire before servicing your machine. 1. Block the machine up off the ground. 2. Rotate the tire so the key slot is upward, then pop off the wheel lock ring with the screwdriver (Figure 16) and save it. Remove the washer and slide the wheel off. To Replace the Front Wheels Leave the key in place (if possible) and slide the wheel back on.
Note: Turn the nut only 1/4 turn at a time, and then test the brake to see if the adjustment worked. If needed, adjust the nut another 1/4 turn and test again. Brake Cable Adjustment The brake cable is factory set (Figure 19). If you think the brake cable needs to be adjusted, you may actually need to replace the brake pads. See below. To Change the Brake Pads If your DR® POWERWAGON™ rolls on slopes when the brake is set, and you have tried adjusting the brake, the brake pads may need to be replaced.
The caliper contains four small parts: the brake pad, the backing plate, and two small actuator pins (Figures 22 & 23). As you let the caliper hang from its attaching hardware, keep track of these parts as they could fall out. Clean away any debris from these parts and the inside of the caliper. 3. Pull the brake disc off the keyed shaft (Figure 24). Be careful not to lose the shaft key. Remove the old brake pad from behind the disc. Next, replace it with a new brake pad, then reinstall the brake disc. 4.
To Adjust the Throttle Cable ! WARNING: Always disconnect the spark plug wire before servicing your machine. CAUTION: Adjusting the throttle is a delicate procedure. There is only a few rpm difference between the engine's idle speed and engagement of the centrifugal clutch. The Throttle Cable is set at the factory and generally no service is required. However, when replacing the throttle cable it is important to follow these steps: Tools Needed: • 5/16 wrench or socket.
To Adjust the Shift Lever If you are unable to shift into reverse or 4th gear, the shift lever and tie rod need to be adjusted. Tools Needed: • 1/2" box or socket wrench • 1/2" box or open-end wrench • 9/16” box or open end wrench ! WARNING: Always disconnect the spark plug wire before servicing your machine. 1. Move the shift lever into the reverse position. 2. Loosen and remove the tie rod nut and bolt from the transaxle arm with the wrenches (Figure 27). Remove the tie rod from the transaxle arm. 3.
To Remove or Replace the Stake Body or the Molded Body Tool Needed: • (2) 1/2" open-end or box wrenches ! WARNING: Always disconnect the spark plug wire before servicing your machine. 1. Position the machine on a level surface. Set the parking brake. 2. Tip the bed forward. 3. Remove the four sets of nuts and bolts, as shown (Figure 29). 4. Carefully lift and remove the body. 5. Follow these instructions in reverse to attach other body.
End of Season ! WARNING: Always disconnect the spark plug wire before servicing your machine. Note: See your engine manufacturer's owner's manual for care and maintenance of the engine. 24 Run the engine dry to empty the carburetor. Or, if you prefer, add the recommended amount of gasoline stabilizer to the fuel in the tank. Run the engine for 2-3 minutes to allow the stabilizer to reach the carburetor. Pull the starter handle slowly until resistance is felt due to compression, then stop.
Beginning of Season Fill the gas tank with fresh, unleaded gas. (See your engine manufacturer's operator's manual for care and maintenance of the engine.) Fill the gas tank completely for an easier start. Note: If you have treated gas with stabilizer in your engine, this step is not necessary. Electric-starting models: Charge and reinstall the battery after winter storage. Clean/replace the air filter. Take out and clean the spark plug. Check the gap and replace the plug if necessary.
Troubleshooting ! WARNING: Always disconnect the spark plug wire before servicing your machine. Refer to the engine manufacturer's operator's manual for care and maintenance of the engine. Engine Engine won't start ⇒ ⇒ ⇒ Engine lacks power Engine skips, pops, misses, shakes Engine smokes ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ Battery Engine won't start with key Alternator isn't recharging the battery 26 Check for adequate, fresh fuel. If the fuel is old or dirty, change it.
Shifting Machine is hard to get into reverse or high gears Wheels Lacks traction Wheels won't turn ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ POWERWAGON™ Safety & Operating Instructions Shift lever may need adjusting. See page 18. Is the load even in the bed? The more weight over the wheels the better the traction. Try a lower gear. If you're working on rough terrain with Turf Tires, you may want to consider the All-Terrain Tires. Call 1-800-DR-OWNER(376-9637)for information.
1-Year Limited Warranty Terms and Conditions The DR POWERWAGON™ is warranted for one (1) year against defects in materials or workmanship when put to ordinary and normal consumer use; ninety (90) days for any other use. The engine is warranted separately by the engine manufacturer. 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.
Daily Checklist for the DR® POWERWAGON™ 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 gas tank with fresh, unleaded gasoline, making sure the gas valve on the bottom of the tank is open. Always close the gas valve when storing your machine. AIR FILTER: A clean air filter will mean a much easier starting and cooler running engine.
