DR® POWERWAGON-PRO SAFETY & OPERATING INSTRUCTIONS READ AND UNDERSTAND THIS MANUAL AND ALL INSTRUCTIONS BEFORE OPERATING THE DR POWERWAGON-PRO.
Table of Contents CHAPTER 1: INTRODUCING THE DR POWERWAGON-PRO ............................................1 CHAPTER 2: GENERAL SAFETY RULES ................................................................................2 CHAPTER 3: SETTING UP YOUR DR POWERWAGON-PRO...............................................8 CHAPTER 4: OPERATING YOUR DR POWERWAGON-PRO.............................................12 CHAPTER 5: MAINTAINING THE DR POWERWAGON-PRO ...........................................
CHAPTER 1: INTRODUCING THE DR POWERWAGON-PRO This manual will help you set up and safely operate your new DR POWERWAGON-PRO. Careful adherence to the safety and operating instructions in this manual will ensure many years of productive use. Please let us know of any questions you may have. We want to answer them as quickly as possible. When you do call, please have your order number, or serial number handy.
CHAPTER 2: GENERAL SAFETY RULES READ THIS SAFETY & OPERATING INSTRUCTIONS MANUAL BEFORE YOU USE THE DR POWERWAGONPRO. BECOME FAMILIAR WITH THE SERVICE RECOMMENDATIONS TO ENSURE THE BEST PERFORMANCE FROM YOUR MACHINE. Labels Your DR POWERWAGON-PRO 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.
Protecting Yourself 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-PRO. IF YOU HAVE SAFETY SHOES, WE RECOMMEND WEARING THEM.
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-PRO 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.
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.
General Safety • THE DR POWERWAGON-PRO 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-PRO IS NOT A PLAYTHING. EXERCISE EXTREME CAUTION AT ALL TIMES.
• SEE MANUFACTURER’S INSTRUCTIONS FOR PROPER OPERATION AND INSTALLATION OF ACCESSORIES. ONLY USE ACCESSORIES APPROVED BY COUNTRY HOME PRODUCTS, INC. • 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 MACHINE IN A SAFE MANNER. CALL TOLL-FREE 1-800-DR-OWNER (376-9637) FOR ASSISTANCE.
CHAPTER 3: SETTING UP YOUR DR POWERWAGON-PRO This chapter outlines a few simple steps you will need to follow to set up your new machine before you use it. It may be helpful to familiarize yourself with the controls and features on your DR POWERWAGON-PRO by reviewing the picture on this page before beginning the steps outlined in this chapter.
Unpacking the DR POWERWAGON-PRO Tools & Supplies Needed: • • • • • • Screwdriver Hammer Knife Gloves Eye protection Metal shears ALWAYS WEAR EYE PROTECTION WHEN CUTTING THE BANDING. THE BANDING MAY HAVE A LOT OF TENSION ON IT AND MAY SNAP, STRIKING YOU WHEN CUT. ALWAYS STAND TO ONE SIDE WHEN CUTTING THE BAND. 1. Stand to one side and cut the banding. 2. Remove the top of the carton. Cut the cardboard top to bottom on one of the narrow sides of the box and peel it off the pallet.
Adding Oil and Gasoline YOU MUST ADD OIL BEFORE STARTING THE ENGINE. THIS MACHINE 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. Engine Oil Capacity Briggs & Stratton 6.75 Torque, Quantum 20 oz. (0.60 L) Tool Tray TO GET AN ACCURATE READING WHEN CHECKING THE OIL LEVEL: • THE MACHINE SHOULD BE ON A LEVEL SURFACE.
Connect the Battery Wires Connect the red wires to each other (Figure 3). The black wires were connected at the factory. Red Wires Connected Figure 3 Contact us at www.DRpower.
CHAPTER 4: OPERATING YOUR DR POWERWAGON-PRO This chapter covers the procedures for starting and stopping your new DR POWERWAGON-PRO and discusses basic operation features. Before Starting the Engine 1. Check the oil level every time you use the machine (See Figure 2 on page 10). 2. Check the gas level (Figure 2). 3. Check the tires for proper inflation. 4. Make sure the Dump Latch is secured. 5.
Manual Recoil Starting NOTE: Manual recoil starting can be used for both ElectricStarting and Manual-Starting models. Choke Lever 1. Move the Shift Lever to the "N" (Neutral) position (Figure 6 on page 12). 2. Set the Choke Lever on the Engine to the CHOKE position (to the RUN position if the Engine is already warm, Figure 7). 3. Turn the Key to the START position (Figure 6 on page 12). 4.
Stopping BE CAREFUL WHEN TRANSPORTING HEAVY LOADS WITH YOUR DR POWERWAGON-PRO. IF THE PARKING 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. 1. Release the Throttle (Figure 5 on page 12). 2. Set the Parking Brake by squeezing the Parking Brake Lever on the right Handlebar and lifting the Parking Brake Lock (Figure 4 on page 12). 3. Shift to "N" (Neutral, Figure 6 on page 12). 4.
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 WITH A MAXIMUM LOAD OF 800 LBS. NEVER OPERATE ON SLOPES GREATER THAN 20°. • Never operate the DR POWERWAGON-PRO on slopes greater than 20 degrees (Figure 8). This is for safety and proper Engine operation.
Dumping - Manually NOTE: For safety reasons, the DR POWERWAGON-PRO Bed is designed NOT to dump automatically once you release the Dump Lever. You must pull the Dump Handle back then lift the back of the Bed to cause it to tip forward. Dump Lever Handle 1. Remove the Front Panel. 2. Stand at the rear of the Bed. 3. Pull the Handle on the Dump Lever (Figure 9), and then pull up on the rear of the Bed to dump the load (Figure 10). 4. After unloading, push the Bed back down into place by hand.
Electric Dump System - Optional The Electric Dump System brings new conveniences to the function of your DR POWERWAGON-PRO. We have included some operating hints and precautions. Please review them carefully. • EVEN DISTRIBUTION OF BED LOADS REMAINS AN IMPORTANT FACTOR IN THE OPERATION OF THIS EQUIPMENT. • CHANGING THE LOCATION AND/OR QUANTITY OF THE LOAD IN THE DUMP BED WILL AFFECT THE HANDLING PROPERTIES OF THE MACHINE. • ALWAYS SET THE PARKING BRAKE WHEN YOUR MACHINE IS STOPPED.
CHAPTER 5: MAINTAINING THE DR POWERWAGON-PRO Regular maintenance is the way to ensure the best performance and long life of your machine. Please refer to this Manual and the Engine Owner's Manual for maintenance procedures. Service intervals listed in the checklist below supercede those listed in the Engine Owner's Manual. SOME OF THE FOLLOWING PROCEDURES REQUIRE ACCESS TO THE UNDERSIDE OF THE MACHINE.
Battery Care (For Electric-Starting models only) 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.
Lubrication 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. Your DR POWERWAGON-PRO was lubricated at the Factory. The transmission is factory sealed and lubricated for life with 16 ounces of 90-weight gear oil. The operator needs only to provide engine lubrication, wheel and cable lubrication.
Changing the Engine Oil 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.
Removing and Replacing the Belt 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. USE ONLY DR BELTS ON YOUR MACHINE. THEY HAVE BEEN THOROUGHLY TESTED AND PROVEN FOR MANY HOURS OF USE. Tools Needed: • 7/16" Socket and extension • 9/16" Socket • 3/8" Wrench 1. Position the machine on a level surface and set the Parking brake. 2.
Removing and Replacing the Front Wheels 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. Tools Needed: • • • Blade Screwdriver Eye protection Pliers 1. Block the machine up off the ground so that the Front Wheels spin freely. 2.
Adjusting the Parking Brake NOTE: If your DR POWERWAGON-PRO rolls on slopes when the Parking Brake is set, or if you cannot get the Parking Brake to set, it needs to be adjusted (Figure 18). 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. Tool Needed: • Brake Assembly 1/2" wrench or socket 1.
Parking Brake Cable Adjustment NOTE: The Parking Brake Cable is factory set (Figure 20). If you think the Brake Cable needs adjustment, you may actually need to replace the Brake Pads. See below. Changing the Parking Brake Pads 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.
NOTE: The Caliper contains four (4) small parts: the Brake Pad, the Backing Plate, and two (2) small Actuator Pins (Figures 22 and 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 22) being careful not to lose the Shaft Key. 4.
Replacing the Throttle Cable 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. 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. NOTE: The Throttle Cable is set at the factory, and generally, no service is required.
3. Remove the Throttle from the Handlebar with a 5/16" Wrench or Socket (Figure 25 on page 27). 4. Place the new Throttle with Cable on the Handlebar and fasten. 5. Replace the Operator Presence Lever on the Handlebar and fasten. 6. Route the Throttle Cable the same as the old Cable, being careful not to bend or kink the Cable. 7. Place the Z-Bend end of the Throttle Cable into the small hole on the Throttle Plate on the Engine.
Adjusting the Shift Lever If you are unable to shift into Reverse or 4th gear, the Shift Lever and Tie Rod need to be adjusted. 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. Tools Needed: • 1/2" Box Wrench or Socket • 1/2" Box or Open-End Wrench • 9/16" Box or Open-End Wrench 1. Move the Shift Lever (Figure 26) into the Reverse position.
Removing and Replacing the Stake Body or Molded Body 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. Tools Needed: • (2) 1/2" Open-End or Box Wrenches 1. Position the machine on a level surface and set the Parking Brake. 2. Tip the Bed forward. 3. Remove the four (4) sets of Nuts and Bolts securing the Body (Figure 29). Nuts & Bolts to remove.
Removing and Replacing the Cinder Blocks 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. Tool Needed: • 7/16" Wrench 1. 2. 3. 4. 5. Position the machine on a level surface and set the Parking Brake. Tip the Bed forward. Loosen the Bolts and Lock Nuts with a 7/16" Wrench on the Front and the Rear of the Weight Rack Block Strap (Figure 30).
CHAPTER 6: TROUBLESHOOTING AND WARRANTY Most problems are easy to fix. Consult the Troubleshooting Table for common problems and their solutions. If you continue to have trouble, call a Technical Support Representative at Country Home Products. Troubleshooting Table 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.
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. SYMPTOM The Engine will not start using Electric-Start. (Please refer to the Engine Owner’s Manual for Engine-specific procedures.) The Engine lacks power or is not running smoothly. (Please refer to the Engine Owner’s Manual for Engine-specific procedures.
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. SYMPTOM The Belt frays or rolls over the Pulley. POSSIBLE CAUSE Machine is hard to get into Reverse. ⇒ The Shift Lever may need adjusting. See page 29. Wheels pulling left or right. ⇒ Check the tire(s) pressure. See page 9. Machine lacks traction. ⇒ The load may be uneven in the Bed.
CHAPTER 7: PARTS LISTS, SCHEMATIC DIAGRAMS AND WARRANTY Parts List - Main Frame Assembly NOTE: Part numbers listed are available through DR Power Equipment. Not all parts appear on all diagrams. Ref# Part# Description 01 Engine, 6.75 TQ, B&S, E/S Engine, 6.75 TQ, B&S, M/S Battery, 17AH, 12V Clamp, Battery, 7-1/8"W x 5.5"H Wire, 6.0", Battery, Positive Wire, 6.
Schematic - Main Frame Assembly 090324 36 DR® POWERWAGON-PRO
Parts List - Main Axle Assembly NOTE: Part numbers listed are available through DR Power Equipment. Not all parts appear on all diagrams.
Schematic - Main Axle Assembly 38 DR® POWERWAGON-PRO
Parts List - Stake Body Assembly NOTE: Part numbers listed are available through DR Power Equipment. Not all parts appear on all diagrams. Ref# 19 44 45 47 48 65 79 80 82 83 87 102 106 112 123 124 126 158 175 192 Part# 109131 110101 110431 108771 109401 109241 110751 110761 111081 109251 111531 111591 111321 111651 110991 110981 112311 112391 190521 164211 Description Bolt, 5/16"-18 x 1-1/2", Carriage, Gr2, ZP Frame, Flat Bed Headboard, Flat Bed Arm, Dump Bushing, .375" ID, .50" OD, 1.
Schematic - Stake Body Assembly 40 DR® POWERWAGON-PRO
Parts List - Handlebar/Controls Assembly NOTE: Part numbers listed are available through DR Power Equipment. Not all parts appear on all diagrams.
Schematic - Handlebar/Controls Assembly 070119 42 DR® POWERWAGON-PRO
Parts List and Schematic - Molded Body Assembly NOTE: Part numbers listed are available through DR Power Equipment. Not all parts appear on all diagrams. Ref# Part# Description Ref# Part# Description 19 109131 26 47 48 57 79 80 82 87 112311 108771 109401 110211 110751 110761 111081 111531 Bolt, 5/16"-18 x 1-1/2", Carriage, Gr2, ZP Spacer, .327" ID, .500" OD, 1.5" L Arm, Dump Bushing, .375" ID, .50" OD, 1.
Parts List and Schematic – Electric Dump NOTE: Part numbers listed are available through DR Power Equipment. Not all parts appear on all diagrams.
DR® POWERWAGON-PRO 2-Year Limited Warranty Terms and Conditions The DR® POWERWAGON-PRO 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. The Engine manufacturer warrants the Engine separately. 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.
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. Daily Checklist for the DR POWERWAGON-PRO To help maintain your DR 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.
