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Summary of Contents for DR POWERWAGON-PRO
- Page 1 ® POWERWAGON-PRO SAFETY & OPERATING INSTRUCTIONS READ AND UNDERSTAND THIS MANUAL AND ALL INSTRUCTIONS BEFORE OPERATING THE DR POWERWAGON-PRO.
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Page 2: Table Of Contents
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 ...........18 CHAPTER 6: TROUBLESHOOTING AND WARRANTY .............32 CHAPTER 7: PARTS LISTS, SCHEMATIC DIAGRAMS AND WARRANTY ......35... -
Page 3: Chapter 1: Introducing The Dr Powerwagon-Pro
THIS INSTRUCTION COULD RESULT IN DAMAGE TO YOUR MACHINE OR PROPERTY. Tip: This is a helpful hint to guide you in getting the most out of your DR POWERWAGON-PRO. Tools Needed: This indicates you will need a special tool to perform a maintenance function on your machine. -
Page 4: Chapter 2: General Safety Rules
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 DR POWERWAGON-PRO as you assemble and before you operate the machine. Replace damaged or missing safety and information labels immediately. - Page 5 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. DO NOT USE THE MACHINE WHILE BAREFOOT OR WEARING OPEN SANDALS.
- Page 6 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-PRO ENGINE IF CHILDREN ENTER THE WORK AREA. • BEFORE, AND WHILE MOVING BACKWARDS, LOOK BEHIND, AND DOWN FOR SMALL CHILDREN.
- Page 7 PROPERLY DISPOSE OF THE WASTE. • ALLOW THE ENGINE TO COOL COMPLETELY BEFORE STORING THE DR POWERWAGON-PRO 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.
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Page 8: General Safety
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: •... - Page 9 This also applies to operation on US Forest Lands. All DR POWERWAGON-PROS shipped to California and Washington State are provided with spark arresters. Failure of the owner/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.
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Page 10: 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. - Page 11 Be careful of the staples. 3. Pry off the fasteners and cut any ties holding the machine to the pallet. 4. Roll the DR POWERWAGON-PRO off the pallet. Do not discard your pallet and packaging material until you are fully satisfied with your machine.
- Page 12 Be careful not to overfill. 3. 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 2 ® POWERWAGON-PRO...
- Page 13 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.com...
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Page 14: Before Starting The Engine
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). - Page 15 ALWAYS RELEASE THE THROTTLE WHEN SHIFTING TO AVOID DAMAGING THE GEARS. The DR POWERWAGON-PRO has a four-speed forward transmission and single-speed reverse. Use the lower gears for slower speeds, heavy loads, or more power, and the higher gears for transport.
- Page 16 OPERATE ON SLOPES GREATER THAN 20°. PLACING MORE WEIGHT IN THE BED MAY BE DANGEROUS TO THE OPERATOR, AND CAN PERMANENTLY DAMAGE THE UNIT. • When loading your DR POWERWAGON-PRO keep in mind the bulk and weight of what you will be hauling, and the terrain you will be crossing. •...
- Page 17 20° Max • On a slope, a heavy load will tend to shift. When using your DR POWERWAGON-PRO, keep in mind that loads tend to shift to the downhill side of the body. Secure Figure 8 your load in the Bed to limit the shifting of the load on slopes.
- Page 18 Be sure the Dump Lever latches securely. Figure 9 NOTE: The Bed of the DR POWERWAGON-PRO 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.
- Page 19 With the Bed partially tipped, you can move your DR POWERWAGON-PRO in reverse while the material flows from the front of the Bed. This is especially helpful in road maintenance and similar work.
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Page 20: Chapter 5: Maintaining The Dr Powerwagon-Pro
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. - Page 21 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.
- Page 22 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.
- Page 23 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. Tools &...
- Page 24 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.
- Page 25 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: •...
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Page 26: Adjusting The Parking Brake
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. - Page 27 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: If your DR POWERWAGON-PRO rolls on slopes when the Parking Brake is set, and you have tried adjusting the Brake, the Brake Pads may need replacement.
- Page 28 Adjustment Nut 1/4 turn with a 1/2" wrench. See “Adjusting the Parking Brake” on page 24. NOTE: Check the Parking Brake periodically and adjust accordingly. Parking Brake Lever Actuator Pins Brake Disk Backing Plate Brake Pad Brake Pads Caliper Figure 22 Figure 23 ® POWERWAGON-PRO...
- Page 29 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.
- Page 30 Cable Clamp and the Throttle Plate. 10. Start the Engine and check the operation of the machine. The DR POWERWAGON-PRO should idle smoothly, but should not move while idling, and should not jump or creep after shifting into gear.
- Page 31 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.
- Page 32 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. NOTE: The 4th set of & Nuts Bolts is hidden. Figure 29 ® POWERWAGON-PRO...
- Page 33 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: •...
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Page 34: Chapter 6: Troubleshooting And Warranty
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, call 1-800-DR-OWNER (376-9637) for assistance. ® POWERWAGON-PRO... - Page 35 Engine-specific periodically charged. See the Battery Care section on page 19. procedures.) ⇒ If the Battery is charged and your DR POWERWAGON-PRO still will not start, call 1-800-DR-OWNER (376-9637) for assistance. ⇒ Check the Throttle travel and adjustment. The Engine lacks power or is not ⇒...
- Page 36 ⇒ The Drive Belt may be on the wrong side of the Pulley. See page 22. ⇒ If the Wheels still will not turn, call 1-800-DR-OWNER (376-9637) for assistance. ⇒ There is a Fuse under the Control Panel. Check the Fuse and replace if needed.
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Page 37: Chapter 7: Parts Lists, Schematic Diagrams And Warranty
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 Ref# Part# Description 117 160351 Tie Rod, 39.09" Rod & Ball Ends 253871 Engine, 6.75 TQ, B&S, E/S... - Page 38 Schematic - Main Frame Assembly 090324 ® POWERWAGON-PRO...
- Page 39 Parts List - Main Axle Assembly NOTE: Part numbers listed are available through DR Power Equipment. Not all parts appear on all diagrams. Ref# Part# Description 108921 Flange, Ball Bearing, 2-Hole 152171 Bearing, Ball, 3/4" Bore 151181 Bracket, Brake Cable, Orange 187631 Cable, Brake, 73-1/2"...
- Page 40 Schematic - Main Axle Assembly ® POWERWAGON-PRO...
- Page 41 Parts List - Stake Body Assembly NOTE: Part numbers listed are available through DR Power Equipment. Not all parts appear on all diagrams. Ref# Part# Description 109131 Bolt, 5/16"-18 x 1-1/2", Carriage, Gr2, ZP 110101 Frame, Flat Bed 110431 Headboard, Flat Bed 108771 Arm, Dump 109401 Bushing, .375"...
- Page 42 Schematic - Stake Body Assembly ® POWERWAGON-PRO...
- Page 43 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 187631 Cable, Brake, 73-1/2" 164341 Control Panel 161531 Label, Control Panel 164301 Frame, Main 164311 Handlebar, RH...
- Page 44 Schematic - Handlebar/Controls Assembly 070119 ® POWERWAGON-PRO...
- Page 45 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 109131 Bolt, 5/16"-18 x 1-1/2", Carriage, Gr2, 111591 Bolt, 5/16"-18 x 2-1/2", HCS 111321 Bolt, 5/16"-18 x 4", HCS...
- Page 46 Parts List and Schematic – Electric Dump NOTE: Part numbers listed are available through DR Power Equipment. Not all parts appear on all diagrams. Ref# Part# Description 181481 Bracket, Bed Not Illustrated 111591 Bolt, 5/16"-18 x 2-1/2" 181511 Bracket, Switch 187101 Pin, Clevis, 3/8"...
- Page 47 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.
- Page 48 Electric starting models: Remove the Battery and keep it in a cool, dry place when the DR POWERWAGON-PRO 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 19.
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Jacking up the power wagon - where safe to place the hydraulic jack.