DR POWERWAGON-PRO, Manual

Page 1: ...DR POWERWAGON PRO SAFETY OPERATING INSTRUCTIONS READ AND UNDERSTAND THIS MANUAL AND ALL INSTRUCTIONS BEFORE OPERATING THE DR POWERWAGON PRO...

Page 2: ...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 TROUBLESHOO...

Page 3: ...ntions used in this manual THIS INDICATES A HAZARDOUS SITUATION WHICH IF NOT AVOIDED COULD RESULT IN DEATH OR SERIOUS INJURY THIS INDICATES A HAZARDOUS SITUATION WHICH IF NOT AVOIDED COULD RESULT IN M...

Page 4: ...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 Take a mom...

Page 5: ...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 PRO ALL...

Page 6: ...REATER THAN 20 DEGREES OR ANY EXCESSIVELY STEEP SLOPES OPERATE ON WET OR SLIPPERY SLOPES REDUCED TRACTION COULD RESULT IN SLIPPING PARK THE DR POWERWAGON PRO ON A STEEP GRADE OR SLOPE Safety for Child...

Page 7: ...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 SP...

Page 8: ...SPEED CAN BE DANGEROUS OPERATE THE MACHINE IN THE LOWEST GEAR THAT IS SATISFACTORY TO DO THE JOB USE CAUTION WHEN MOVING DOWNHILL AND BRAKING APPLY THE PARKING BRAKE SLOWLY TO AVOID TIPPING FORWARD W...

Page 9: ...o 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 i...

Page 10: ...AGON PRO by reviewing the picture on this page before beginning the steps outlined in this chapter DR POWERWAGON PRO Controls and Features Figure 1 Brake Control Right Handlebar Removable Front Panel...

Page 11: ...SURE TO FILL YOUR ENGINE WITH OIL AND GAS BEFORE USE SEE PAGE 10 Check the Tire Pressure Tools Needed Tire Pressure Gauge Air Compressor 1 Remove the Valve Stem Protective Cap and check the tire press...

Page 12: ...your machine Please refer to your Engine Owner s Manual for detailed oil information NOTE You must remove the tool tray to access the Oil and Fuel Reservoirs 1 Place the machine on a level surface an...

Page 13: ...Contact us at www DRpower com 11 Figure 3 Connect the Battery Wires Connect the red wires to each other Figure 3 The black wires were connected at the factory Red Wires Connected...

Page 14: ...gain NOTE The DR POWERWAGON PRO 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...

Page 15: ...igure 5 on page 12 to the desired speed See the Engine Owner s Manual for information on cold weather starting Operating ALWAYS RELEASE THE THROTTLE WHEN SHIFTING TO AVOID DAMAGING THE GEARS The DR PO...

Page 16: ...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 Keep the load balanced and secured Always distribute the loa...

Page 17: ...e 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 W...

Page 18: ...ar of the Bed to dump the load Figure 10 4 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 PRO is balanced so you ca...

Page 19: ...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 DRPOWERWAGON PRO...

Page 20: ...y or dusty conditions Procedure Before Each Use Every 25 Hours Every 100 Hours Check Operator Presence Lever S Check Engine Oil Level S Check General Equipment Condition S Lubricate Grease Fittings S...

Page 21: ...he 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...

Page 22: ...Grease 1 There are two 2 Grease Fittings on the Swivel Wheel one 1 at the top front of the Wheel Bracket and one 1 toward the center of the Wheel Figure 11 Grease these two 2 Fittings with 2 lithium...

Page 23: ...Liquid Vac Oil Drainer item 16145 optional accessory sold separately 1 Using a 3 8 Ratchet and Extension remove the Oil Drain Plug from the bottom of the Engine Figure 14 and drain the oil 2 Replace...

Page 24: ...to lessen the tension on the Belt and slide the Belt from the Idler Pulley Figure 15 5 Remove the Belt from the Transmission Pulley at the front of the machine Figure 16 6 Remove the Belt from the Cl...

Page 25: ...2 Rotate the Tire so the Key Slot is upward then pop off the Wheel Lock Ring with a Screwdriver Figure 17 and save it Remove the Washer and slide the Wheel off 3 To replace the Wheel leave the Key in...

Page 26: ...rying to roll the machine It should not move in either direction with the Parking Brake set 4 If it does move turn the Adjustment Nut on the Transaxle Figure 19 1 4 turn clockwise with a 1 2 Wrench to...

Page 27: ...n slopes when the Parking Brake is set and you have tried adjusting the Brake the Brake Pads may need replacement Tools Supplies Needed 1 2 Wrench or Socket Mat or container for loose parts NOTE You m...

Page 28: ...ns the Backing Plate and the second Brake Pad Figure 23 Make sure the Brake Arm Assembly is in the upright position and the recessed cutout on the Caliper is facing up with the Plate to the rear Be su...

Page 29: ...ow these steps Tools Needed 5 16 Wrench or Socket Phillips Screwdriver 1 Loosen the Screw on the Throttle Cable Clamp Bowden clamp with the Wrench or Socket so the Throttle Cable can slide below it It...

Page 30: ...has two 2 holes and the Cable goes into the smaller hole from the bottom side Place the Throttle Cable Sheath under the Cable Clamp Figure 24 on page 27 8 Make sure that the Throttle Plate is all the...

Page 31: ...ure 27 and then remove the Tie Rod from the Transaxle Arm 3 Fully extend the Transaxle Arm toward the front of the machine this will put the Transmission into Reverse gear Figure 28 4 Loosen the Lock...

Page 32: ...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...

Page 33: ...THE SPARK PLUG Tool Needed 7 16 Wrench 1 Position the machine on a level surface and set the Parking Brake 2 Tip the Bed forward 3 Loosen the Bolts and Lock Nuts with a 7 16 Wrench on the Front and th...

Page 34: ...n the Engine pulley by hand with the Spark Plug wire off If it turns the Recoil is broken or jammed Call 1 800 DR OWNER 376 9637 for assistance The Engine will not start manually Please refer to the E...

Page 35: ...ill not start call 1 800 DR OWNER 376 9637 for assistance The Engine lacks power or is not running smoothly Please refer to the Engine Owner s Manual for Engine specific procedures Check the Throttle...

Page 36: ...POWERWAGON PRO is in gear Check that the Parking Brake is off The Drive Belt may be loose or off the Pulley See page 22 The Drive Belt may be on the wrong side of the Pulley See page 22 If the Wheels...

Page 37: ...111491 Bolt 1 4 20 x 1 HCS 96 165131 Bolt 3 8 24 x 1 1 4 HCS Gr8 99 134431 Bolt 5 16 18 x 1 1 2 HCS 100 150451 Bolt 5 16 18 x 1 3 4 HCS 101 123361 Bolt 5 16 18 x 1 1 4 HCS 110 180991 Screw 10 24 x 1 P...

Page 38: ...36 DR POWERWAGON PRO Schematic Main Frame Assembly 090324...

Page 39: ...x 1 1 2 50 160521 Shim 3 4 ID 1 0 OD 1 4 L 52 112371 Washer Flat 10 24 USS 53 112381 Washer Flat 1 4 USS 58 106401 Key woodruff 3 16 x 3 4 73 110691 Nut 5 16 18 ZP 80 110761 Nut Nylon Lock 5 16 18 91...

Page 40: ...38 DR POWERWAGON PRO Schematic Main Axle Assembly...

Page 41: ...Left Corner 79 110751 Nut Nylon Lock 3 8 16 80 110761 Nut Nylon Lock 5 16 18 82 111081 Plug 1 x 1 OD 83 109251 Bracket Right Corner 87 111531 Bolt 3 8 16 x 2 1 4 HCS 102 111591 Bolt 5 16 18 x 2 1 2 HC...

Page 42: ...40 DR POWERWAGON PRO Schematic Stake Body Assembly...

Page 43: ...1 3 4 88 120301 Screw 3 8 16 x 1 1 2 Trilobe Gr2 ZP 99 134431 Bolt 5 16 18 x 1 1 2 HCS 115 108871 Lever Shift Upper 116 110221 Grip Shift Handle 158 112391 Washer Flat 3 8 USS 161 188251 Wire Harness...

Page 44: ...42 DR POWERWAGON PRO Schematic Handlebar Controls Assembly 070119...

Page 45: ...D 500 OD 1 5 L 47 108771 Arm Dump 48 109401 Bushing 375 ID 50 OD 1 13 L 57 110211 Grip Handle 4 x 1 1 4 79 110751 Nut Nylon Lock 3 8 16 80 110761 Nut Nylon Lock 5 16 18 82 111081 Plug 1 x 1 OD 87 1115...

Page 46: ...d 2 111591 Bolt 5 16 18 x 2 1 2 3 187101 Pin Clevis 3 8 x 1 1 2 4 150451 Bolt 5 16 18 x 1 3 4 5 181471 Bracket Upright 6 134431 Bolt 5 16 18 x 1 1 2 7 112411 Washer Flat 5 16 USS 8 151921 Clip Hitch P...

Page 47: ...e 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 F...

Page 48: ...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 Compl...