Owner's Manual - DR Power Equipment
Contents
1. DR POWERWAGON PREMIER SAFETY amp OPERATING INSTRUCTIONS IN WARNING READ AND UNDERSTAND THIS MANUAL AND ALL INSTRUCTIONS BEFORE OPERATING THE DR POWERWAGON PREMI HANK you Congratulations on your purchase of a new DR POWERWAGON PREMIER We have done our utmost to ensure that your DR POWERWAGON PREMIER will be one of the most trouble free and satisfying pieces of equipment you have ever owned 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 serial number or order number handy For technical assistance please call Toll Free 1 800 DR OWNER 376 9637 and one of our Technical Support Representatives will be happy to help you We also hope to hear from you on how much you like your new helper In addition please tell your friends about your new DR POWERWAGON PREMIER Having DR Owners spread the word about our products and our way of doing business is the best advertising we can have and the best way to help us provide even better service in the years to come THANKS ONCE AGAIN for all of us at Pr Country Home Products Inc SALES MANAGER COPYRIGHT 92007 Country Home Products Inc All rights reserved DR Power Equipment A division of Country Home Products 127 Meigs Road Vergennes VT 05491 Toll free phone 1 800 DR OWNER 376 9637 Fax 1 802 877 1213 Web site www dr owner com I DR POWERWA2. 16 DR POWERWAGON PREMIER Dumping NOTE For safety reasons the design of the DR POWERWAGON PREMIER Bed is NOT to dump automatically once you release the Dump Lever You must pull the Dump Lever back then lift the back of the Bed to cause it to tip forward 1 Pull the Dump Lever Handle straight out Figure 9 then pull up on the Bed Handle to dump the load Figure 10 2 After unloading push the Bed back down into place by hand Figure 9 PNnorice BE SURE THE DUMP LEVER LATCHES SECURELY NOTE The Bed of the DR POWERWAGON PREMIER 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 In this case you will need to manually remove part of the load from the back of the Bed until the load is light enough to allow the Bed to tip forward when you lift the Bed Handle Bed Handle Figure 10 CALL TOLL FREE 1 800 DR OWNER 17 CHAPTER 5 MAINTAINING THE DR POWERWAGON PREMI ER 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 supersede those listed in the Engine Owner s Manual WHEN PERFORMING ANY MAINTENANCE YOU MUST FIRST SHUT OFF THE ENGINE SET THE PARKING BRAKE WAIT FIVE 5 MINUTES TO ALLOW PARTS
3. 2 1 4 Bolt HCS 1 4 20 x 1 1 4 Bolt HCS 1 4 20 x 1 3 4 Bolt HCS 5 16 18 x 2 1 2 Refit Partit Description 01 223431 223831 05 104831 Battery 17 AH 12 V 06 124511 07 113051 09 114561 Bolt HCS 1 4 20 x 2 16 109341 Stop Bumper 17 164121 Strip Bumper 2 1 2 46 108731 Stop Angle Flat bed 49 106381 51 112411 Washer Flat 5 16 USS 52 112371 Washer Flat 10 24 USS 53 112381 Washer Flat 1 4 USS 54 164301 Frame Main 61 110301 Handle Latch 62 110241 Grip Latch Handle 63 110451 Housing Latch 64 111931 Latch Spring 2 1 4 66 111291 Lower Shift Rod w Arm 78 165391 79 110751 Nut Nylon Lock 3 8 16 80 110761 Nut Nylon Lock 5 16 18 83 110961 Pin Spring 3 16 x 1 84 110731 Nut Nylon Lock 1 4 20 85 110971 Pin Spring 3 16 x 1 3 4 86 114701 Bolt HCS 1 4 20 x 1 2 87 111531 89 119831 Bolt HCS 1 4 20 x 3 4 90 111491 Bolt HCS 1 4 20 x 1 92 160861 93 111481 96 111551 Bolt HCS 3 8 24 x 3 4 97 112481 Washer Lock 1 4 99 111591 36 DR POWERWAGON PREMIER Refit Parti Description 100 101 102 110 114 117 123 127 128 131 136 142 143 146 148 154 158 164 165 167 171 172 175 176 177 181 182 185 187 188 150451 Bolt HCS 5 16 18 x 1 3 4 123361 Bolt HCS 5 16 18 x 1 1 4 180281 Spacer 328 ID 75 OD 25 L 111661 Screw Phillips Pan 12 x 1 160871 Coupling Shift lever 160351 Tie rod 39 09 Rod amp Ball ends 111921 Spring e 500 OD x 067
4. Cable Figure 13 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 amp Supplies Recommended 3 8 Ratchet and extension SAE 30 High Detergent HD Oil for winter use use SAE 5W 30W Suitable container for the old oil Rag or cloth Liquid Vac Oil Drainer item 16145 Optional Accessory sold separately 1 Using 3 8 Ratchet and extension remove the Oil Drain Plug from the bottom of the Engine Figure 14 and drain the oil 2 Replace the Plug and refill the oil to the level indicated on the Dipstick Do not overfill Refer to the Adding Oil and Gasoline section on page 11 Alternate Method 1 Remove the Oil Fill Cap and vacuum the oil from the Engine through the Oil Fill Tube using the recommended Oil Drainer NOTE If you will not be reusing the oil be sure to use environmentally safe disposal procedures in the disposing of the used oil Figure 14 CALL TOLL FREE 1 800 DR OWNER 21 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 PNnorice USE ONLY DR BELTS ON YOUR MACHINE THEY HAVE BEEN THOROUGHLY TESTED AND
5. Parking Brake Cable needs adjustment you may actually need to replace the Parking 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 If your DR POWERWAGON PREMIER rolls on slopes when the Parking Brake is set and you have tried adjusting the Parking Brake the Parking Brake Pads may need replacement Tools amp Supplies Needed e 1 2 Wrench or Socket e Mat or container for loose parts NOTE You may want to remove the Wheel to provide easier access to the Parking Brake area See page 24 1 Find a level area to work The Parking Brake should NOT be engaged Chock the Wheels so the machine cannot move 2 Locate the Parking Brake Caliper at the right front of the machine Figure 23 Remove the two 2 Caliper Bolts holding the Parking Brake Caliper with a 1 2 Wrench and then carefully remove the Caliper Figure 23 26 DR POWERWAGON PREMIER NOTE The Caliper contains four 4 small parts the Brake Pad the Backing Plate and two 2 small Actuator Pins Figures 24 25 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
6. THE DR POWERWAGON PREMI ER This manual will help you set up and safely operate your new DR POWERWAGON PREMIER 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 serial number and or order number handy For technical assistance please call Toll Free 1 800 DR OWNER 376 9637 and one of our Technical Support Representatives will be happy to help you Conventions used in this manual PN WARNING THIS INDICATES A HAZARDOUS SITUATION WHICH IF NOT AVOIDED COULD RESULT IN DEATH OR SERIOUS INJURY PX caution THIS INDICATES A HAZARDOUS SITUATION WHICH IF NOT AVOIDED COULD RESULT IN MINOR OR MODERATE INJURY THIS INFORMATION IS IMPORTANT IN THE USE OF YOUR MACHINE FAILURE TO FOLLOW THIS INSTRUCTION COULD RESULT IN DAMAGE TO YOUR MACHINE OR PROPERTY Tip This is helpful hint to guide you in getting the most out of your DR POWERWAGON PREMIER Tools Needed This indicates you will need a specific tool to perform a maintenance function on your DR POWERWAGON PREMIER NOTE This information may be helpful to you If you are ever unsure about an action you are about to take don t do it Contact Country Home Products Toll Free support at 1 800 DR OWNER 376 9637 for help or info
7. required The Cable is supplied as a complete assembly with the Handle already attached Figure 27 However when replacing the Throttle Cable it is important to follow these steps Tools Needed 1 1 4 Socket Throttle Cable Clamp Z Bend Blade Screwdriver Figure 26 1 Loosen the Screw on the Throttle Cable Clamp with a Screwdriver so the Throttle Cable can slide below it It is not necessary to remove the Clamp Figure 26 2 Remove the Z bend end of the Cable from the Throttle Throttle Assembly Plate Figure 26 underside 3 Remove the two 2 Screws holding the Throttle Assembly Figure 27 to the Control Panel with a 1 4 Socket or Screwdriver Figure 28 4 Tilt and slide the Throttle Assembly down through the Slot in the Control Panel Figure 28 5 Tilt and place the Handle of the new Throttle Assembly up through the Slot in the Control Panel and fasten with two 2 Screws Position the Throttle Handle to IDLE STOP Throttle N v NM NA SN 6 Route the Throttle Cable the same as the old Cable being PAIN careful not to bend kink the Cable 7 Place the Z bend end of the Throttle Cable into the small hole in the Throttle Plate on the Engine The Throttle Plate is a black Tab that protrudes from the Engine below the plastic Air Filter It has two 2 holes and the Cable goes into the smaller hole Place the Throttle Cable Sheath under the Cable Clamp
8. wire 126971 Washer 1 4 ID x 1 OD Fender 112501 Washer Lock 5 16 112581 Wheel Caster 4 10 3 50 4 136601 Leg Tray Frame 180501 Bracket Idler Arm 113071 Pulley Flat Idler 2 1 4 144091 Pulley 2 5 8 V Belt 108971 Belt A82 1 2 x 84 114921 Bracket Belt Retainer 112391 Washer Flat 3 8 USS 112111 Cable Throttle 36 1 2 160461 Throttle Spring Bracket 120891 Spring Throttle Return 180471 Pulley 3 0 V Belt 180791 Guide Engine Belt 114781 Screw Pan Head 10 24 x 5 8 112461 Nylon Washer 39 ID x 1 OD 109411 Bushing 265 ID x 375 OD 180801 Guide Trans Belt 180851 Bolt HCS 1 4 20 x 2 3 4 180511 Guard Belt 180551 Cable Wheel Clutch 180871 Clip Nylon 3 16 Dia Parts Not Shown 193151 Wire 6 0 Battery Positive 193161 Wire 6 5 Battery Negative Schematic Main Frame Assembly 5 05 2006 CALL TOLL FREE 1 800 DR OWNER 37 Parts List Handlebar Controls Assembly NOTE Part numbers listed are available through Country Home Products Inc Label Control Panel Premier Bolt HCS 5 16 18 x 1 3 4 Switch w Key amp Hardware e s Washer 1 2 ID x 3 4 OD Grip Ergonomic 1 Handlebar Lever Op Presence w Wire Screw M6 x 25mm Socket Head Refit Parti Description 14 187631 Cable Brake 73 1 2 33 180521 Control Panel 34 180531 53 112381 Washer Flat 1 4 USS 54 164301 Frame Main 55 164311 Handlebar RH 56 164321 Handlebar LH 57 164331 Cr
9. 2 CHAPTER irnn desert dain 13 OPERATING YOUR DR 13 Before Starting the Engine etasje 13 i E Ge e det 13 Manual Recoil Starting T 14 Operating uuu sal ked R bekay n n e k KENA EKA He fe devot 14 Slade 15 Jc Arce 15 loadings Tp 15 Slopes and Uneven Terrain l end ota ipit ipe keke kek se pep recess 16 Dilane N n a l 17 CHAPTERS ua DD a rrr rrr 18 MAINTAINING THE DR 18 Resular Maintenance iiin tire tib i ekken e eripi ke reb er 18 19 Charging the Battery a kg b wk iba 19 Lubrication asserendo 20 Changing the Engine suni xuy e e dele ele kin uk eta qas Qu 21 Removing and Replacing the Belt ereke kerek eker ek keke keke k r 22 Removing and Replacing the Front Wheels aa 24 A justiri ie Parking e H 25 Parking Brake Cable Adjustment poster keke keke keke 26 Changing the Parking Brake Pads yekeke keke keke k k k ek 26 CALL TOL
10. 24 being careful not to lose the Shaft Key 4 Remove the old Brake Pad from behind the Disc and replace it with a new Brake Pad then reinstall the Brake Disc 5 Replace the Caliper Housing and its parts two 2 Actuator Pins the Backing Plate and the second Brake Pad Figure 25 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 sure that the Parking Brake Lever is pointing up Figure 23 on page 26 Reinstall the two 2 Caliper Bolts and be careful not to over tighten them 6 Test the Parking Brake With the machine on a level surface set the Parking Brake and put the machine in N Neutral If the Parking Brake does not engage or hold tighten the Parking Brake Adjustment Nut 1 4 turn with a 1 2 wrench See Adjusting the Parking Brake on page 25 NOTE Check the Parking Brake periodically and adjust accordingly Parking Brake Lever _ Actuator Pins I Backing Plate Brake Pad I Brake Pads Caliper Figure 24 Figure 25 CALL TOLL FREE 1 800 DR OWNER 27 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 Throttle Cable Throttle Plate NOTE The Throttle Cable is set at the factory and generally service is
11. Belt for wear and hard spots rolls over the File off any nicks on the Pulleys Pulley Check the Belt Guide alignment See pages 22 and 23 U The Belt may be stretched replace it Machine is hard to gt The Shift Lever may need adjusting See page 30 get into Reverse Wheels pulling left Check the tire s pressure See page 10 or right Machine lacks The load may be uneven in the Bed The more weight over the Wheels the better traction the traction U Try a lower gear U If you are 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 The Wheels will not turn Make sure that the DR POWERWAGON PREMIER 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 still will not turn call 1 800 DR OWNER 376 9637 for assistance U U U U U CALL TOLL FREE 1 800 DR OWNER 35 CHAPTER 7 PARTS LISTS SCHEMATI C DIAGRAMS AND WARRANTY Parts List Main Frame Assembly NOTE Part numbers listed are available through Country Home Products Inc Engine 6 25 Torque B amp S e s CA Engine 6 25 Torque B amp S e s Clamp Battery 7 13 W 5 5 H Pad battery 3 5 8 x 2 7 8 Key square 3 16 x 1 1 2 Anchor Wheel Drive Cable Bolt HCS 3 8 16 x
12. E INJURY ALL SLOPES REQUIRE CAUTION IF YOU FEEL UNEASY ON A SLOPE DO NOT USE THE DR POWERWAGON PREMIER ON IT ALWAYS TAKE THE FOLLOWING PRECAUTIONS WHEN USING THIS MACHINE ON SLOPES ALWAYS e TRAVERSE UP AND DOWN THE FACE OF SLOPES NEVER ACROSS EXERCISE EXTREME CAUTION WHEN CHANGING DIRECTION ON SLOPES e WATCH FOR HOLES RUTS OR BUMPS IN THE LANDSCAPE USE 157 GEAR ON SLOPES WITH A MAXIMUM LOAD OF 400 185 NEVER e OPERATE NEAR DROP OFFS DITCHES OR EMBANKMENTS YOU COULD LOSE YOUR FOOTING OR BALANCE OPERATE ON SLOPES GREATER THAN 20 DEGREES OR ANY EXCESSIVELY STEEP SLOPES e OPERATE ON WET OR SLIPPERY SLOPES REDUCED TRACTION COULD RESULT IN SLIPPING PARK THE DR POWERWAGON PREMIER ON A STEEP GRADE OR SLOPE Safety for Children TRAGIC ACCIDENTS CAN OCCUR IF THE OPERATOR IS NOT ALERT TO THE PRESENCE OF CHILDREN CHILDREN ARE OFTEN ATTRACTED TO THE MACHINE AND THE HAULING ACTIVITY NEVER ASSUME THAT CHILDREN WILL REMAIN WHERE YOU LAST SAW THEM e KEEP CHILDREN OUT OF THE WORK AREA AND UNDER THE WATCHFUL CARE OF A RESPONSIBLE ADULT e BE ALERT AND ALWAYS TURN OFF THE DR POWERWAGON PREMIER ENGINE IF CHILDREN ENTER THE WORK AREA e BEFORE AND WHILE MOVING BACKWARDS LOOK BEHIND AND DOWN FOR SMALL CHILDREN NEVER ALLOW CHILDREN TO OPERATE THE DR POWERWAGON PREMIER USE EXTRA CARE WHEN APPROACHING BLIND CORNERS SHRUBS TREES OR OTHER OBJECTS THAT MAY OBSCURE YOUR VISION CALL TOLL FREE 1 800 DR OWNER 5
13. E 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 e WEAR SHOES WITH NON SLIP TREADS WHEN USING YOUR DR POWERWAGON PREMIER IF YOU HAVE SAFETY SHOES WE RECOMMEND WEARING THEM DO NOT USE THE MACHINE WHILE BAREFOOT OR WEARING OPEN SANDALS AVOID WEARING LOOSE CLOTHING OR JEWELRY WHICH CAN CATCH ON THE MACHINE S MOVING PARTS e USE EAR PROTECTORS OR EAR PLUGS RATED FOR AT LEAST 20 DBA TO PROTECT YOUR HEARING e NEVER ALLOW PEOPLE WHO ARE UNFAMILIAR WITH THESE INSTRUCTIONS TO USE THE DR POWERWAGON PREMIER ALLOW ONLY RESPONSIBLE INDIVIDUALS WHO ARE FAMILIAR WITH THESE RULES OF SAFE OPERATION TO USE YOUR MACHINE e NEVER PLACE YOUR HANDS FEET OR ANY PART OF YOUR BODY NEAR OR UNDER ANY MOVING PART WHILE THE MACHINE IS RUNNING e TO BE SAFE DO NOT OPERATE THE MACHINE NEAR SMALL CHILDREN OR PETS AND NEVER ALLOW CHILDREN TO OPERATE THE DR POWERWAGON PREMIER e THE MUFFLER AND ENGINE BECOME VERY HOT AND CAN CAUSE A SEVERE BURN DO NOT TOUCH e NEVER UNDER ANY CONDITIONS REMOVE BEND CUT FIT WELD OR OTHERWISE ALTER STANDARD PARTS ON THE DR POWERWAGON PREMIER THIS INCLUDES ALL SHIELDS AND GUARDS MODIFICATIONS TO YOUR MACHINE COULD CAUSE PERSONAL INJURIES AND WILL VOID YOUR WARRANTY 4 DR POWERWAGON PREMIER Slope Operation SLOPES ARE A MAJOR FACTOR RELATED TO SLIP AND FALL ACCIDENTS WHICH CAN RESULT IN SEVER
14. E WIRE AWAY FROM THE SPARK PLUG TO PREVENT ACCIDENTAL STARTING NEVER CHECK FOR AN IGNITION SPARK WITH THE SPARK PLUG OR SPARK PLUG WIRE REMOVED USE AN APPROVED SPARK TESTER NEVER TAMPER WITH SAFETY DEVICES CHECK THEIR PROPER OPERATION REGULARLY DO NOT CHANGE THE ENGINE GOVERNOR SETTINGS OR MODIFY THE ENGINE SPEED MODIFICATIONS WILL VOID YOUR WARRANTY TO REDUCE FIRE HAZARD KEEP THE ENGINE COOLING FAN AND MUFFLER AREA FREE OF DEBRIS BUILD UP SUCH AS LEAVES GRASS OIL GREASE OR ANY OTHER COMBUSTIBLE MATERIAL NEVER OPERATE THE ENGINE WITHOUT THE MUFFLER INSPECT THE MUFFLER PERIODICALLY AND REPLACE IF NECESSARY IF EQUIPPED WITH A MUFFLER DEFLECTOR INSPECT THE DEFLECTOR PERIODICALLY AND REPLACE IF NECESSARY NEVER OPERATE THE ENGINE WITH THE AIR CLEANER OR COVER OVER THE CARBURETOR AIR INTAKE REMOVED EXCEPT FOR ADJUSTMENT REMOVAL OF SUCH PARTS COULD CREATE A FIRE HAZARD DO NOT USE FLAMMABLE SOLUTIONS TO CLEAN AIR FILTER ALWAYS CHECK FUEL LINES AND FITTINGS FREQUENTLY FOR CRACKS OR LEAKS REPLACE IF NECESSARY 6 DR POWERWAGON PREMIER General Safety e THE DR POWERWAGON PREMIER MUST 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 e KEEPIN MIND THAT THE OPERATOR OR USER IS RESPONSIBLE FOR ACCIDENTS OR HAZARDS OCCURRING TO OTHER PEOPLE THEIR PROPER
15. Figure 26 8 Make sure that the Throttle Plate is all the way back to the 4 Stop position It will normally retract to this position Figure 28 28 DR POWERWAGON PREMIER 9 Tighten the Throttle Cable Clamp Screw making sure that the Throttle Handle is still in the IDLE STOP position The Throttle Cable should have very little or no tension between the Cable Clamp and the Throttle Plate PNnorice IF YOU CLAMP THE CABLE WITH TOO MUCH TENSION BETWEEN THE CABLE CLAMP AND THE THROTTLE PLATE THE ENGINE WILL NOT RETURN TO IDLE PROPERLY 10 Start the Engine and check the operation of the machine The DR POWERWAGON PREMIER should idle smoothly but should not move while idling and should not jump after shifting into gear CALL TOLL FREE 1 800 DR OWNER 29 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 e 1 2 Box or Open end Wrench 9 16 Box or Open end Wrench 1 Move the Shift Lever into the Reverse position Figure 29 2 Loosen and remove the Tie Rod Nut and Bolt from the Transaxle Arm with 1 2 wrenches Figure 30 Remove the Tie Rod from the Transaxle Arm 3 Fully extend the
16. GON PREMIER RI I9I I I I I I IIIII I III I III III I I IIII IIIMIIIKTIOIEIKW lt MIIWKWIW I II II IIIII I I I I IIII IIIIII I I II I I lt KKIHII IS II amp IW HIII HS8SO O Z I ss Table of Contents sud qa a ama apu east needed E eta 1 INTRODUCING THE DR POWERWAGON PREMIER 1 Conventions used EEE EN 1 nidi S 2 GENERAL SAFETY RULES yi ua en tr putent bre Laeta peer s re odan beste irae d pv 2 Labels CE 2 Protecting 4 Slope pappa ia 5 Safety for Child km m c gmmmppppp mm 5 Safety with Gasoline Powered Machines eee eke keke keke ke kek ek 6 General e Uy NNI ON M PEPPER ENTUM 7 A IN LXDICHErOI belarn a 8 Additional Information and Potential erkeke keke 8 U NNE K N EENES 9 SETTING UP YOUR DR POWERWAGON PREMIER 9 DR POWERWAGON PREMIER Controls And 9 Unpacking the DR POWERWAGON PREMIER eere 10 Check the Tire Pressure 10 Adding Oil and Gasoline 1 Connect the Battery 1
17. L FREE 1 800 DR OWNER a Replacing the Throttle Cable M eoe ie til eren 28 Adjusting the Shift ssi kg 30 Adjusting the Wheel Clutch sanse 31 End of Season and Stora g LAN 32 Recycling a Used asahan nala e EW u 32 PAPER 33 TROUBLESHOOTING 5 a S k p x k SEWE asbest DEN KEWE de WER EWE eee 33 Troubleshooting TR i i Vati qan eol 33 CHAPTER tet aw rett iMate Atte ei D dal AG an 36 PARTS LISTS SCHEMATIC DIAGRAMS AND WARRANTY 36 Parts List Main Frame Assembly 36 Schematic Main Frame Assembly uuL toot beet teen edere eere keke 37 Parts List Handlebar Controls Assembly viva 38 Schematic Handlebar Controls Assembly kre ekekekek e 39 Parts List Main Axle Assembly uu n Rr tea era 40 Schematic Main Axle 41 Parts List Molded Body Assembly 42 Schematic Molded Body Assembly uu erkeke po 43 NOTES See dttv bud ea mam m as ye R EATE EEE 44 Daily Checklist for the POWERWAGON PREMIER 46 IV DR POWERWAGON PREMIER CHAPTER I INTRODUCING
18. OUTLET FIRST THEN DISCONNECT THE BATTERY CHARGER WIRES FROM THE BATTERY IF YOU LEAVE THE BATTERY CHARGER WIRES CONNECTED TO THE BATTERY THE BATTERY WILL DISCHARGE ITSELF BACK INTO THE CHARGER CALL TOLL FREE 1 800 DR OWNER 19 Lubrication PN WARNING 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 PREMIER 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 Supplies Needed e SAE 30 Oil e 2 Lithium 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 grease to keep the Wheel spinning freely at least every 25 hours of operation per the Maintenance Checklist on page 18 2 Using SAE 30 Oil lubricate the Parking Brake Lever Cable at the Operator s end and the Wheel Clutch Lever Cable at both ends Figures 12 and 13 Operate the Levers to work the lubricant into the Cables 3 Lubricate the Key Switch with SAE 30 Oil Figure 11 Lubricate Lubricate Figure 12 20 DR POWERWAGON PREMIER l 4 Lubricate
19. PROVEN FOR MANY HOURS OF USE Tools Needed Rear Bolt Front Bolts 7 16 Socket and extension 9 16 Socket 3 8 Wrench Phillips Screwdriver 1 Position the machine on a level surface and set the Parking Brake 2 Tip the Bed forward Figures 9 and 10 on page 17 3 Remove the Belt Guard by removing the two 2 Bolts at the front using a Phillips screwdriver and 3 8 wrench Remove the single Bolt at the rear using a 7 16 socket Figure 15 4 Loosen the Belt Guide Bolts using a 9 16 socket Figure 16 Figure 15 5 Pull on the Idler Arm and Spring to lessen the tension on the Belt and slide the Belt from the Idler Arm and Clutch Pulley Figure 16 6 Remove the Belt from the Transmission Pulley at the front of the machine Figure 17 on page 23 7 Remove the Belt from the Drive Pulley under the Engine Figure 14 on page 21 8 Install the new Belt on the Drive Pulley first then the Transmission Pulley and then the Idler and Clutch Pulleys Make sure the new Belt is INSIDE the Belt Guide Figure 14 on page 21 Idler Arm Figure 16 22 DR POWERWAGON PREMIER Remove Belt from Transmission Pulley Figure 17 9 Squeeze the Wheel Clutch Lever to engage the Clutch The Belt Guides should be perpendicular to and not touching the Belt Figure 18 With the Wheel Clutch engaged adjust the Guides as necessary and tighten the Guide Bolts Figure 16 with the 9 16 socket NOTE When the Whee
20. 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 STORE ALL FUEL AND OIL IN CONTAINERS SPECIFICALLY DESIGNED AND APPROVED FOR THIS PURPOSE AND KEEP AWAY FROM HEAT AND OPEN FLAME AND OUT OF THE REACH OF CHILDREN FILL THE GASOLINE TANK OUTDOORS WITH THE ENGINE OFF AND ALLOW THE ENGINE TO COOL COMPLETELY DO NOT HANDLE GASOLINE IF YOU OR ANYONE NEARBY IS SMOKING OR IF YOU ARE NEAR ANYTHING THAT COULD CAUSE IT TO IGNITE OR EXPLODE REPLACE THE FUEL TANK AND FUEL CONTAINER CAPS SECURELY IF YOU SPILL GASOLINE DO NOT ATTEMPT TO START THE ENGINE MOVE THE MACHINE AWAY FROM THE AREA OF THE SPILL AND AVOID CREATING ANY SOURCE OF IGNITION UNTIL THE GAS VAPORS HAVE DISSIPATED WIPE UP ANY SPILLED FUEL TO PREVENT A FIRE HAZARD AND PROPERLY DISPOSE OF THE WASTE ALLOW THE ENGINE TO COOL COMPLETELY BEFORE STORING THE POWERWAGON PREMIER 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 NEVER MAKE ADJUSTMENTS OR REPAIRS WITH THE ENGINE RUNNING DISCONNECT THE SPARK PLUG WIRE AND KEEP TH
21. Switch Operator Presence Lever Removable Tool Molded Body Manual Recoil not shown Fuel amp Oil Reservoirs All Terrain Tires Figure 1 CALL TOLL FREE 1 800 DR OWNER 9 Unpacking the DR POWERWAGON PREMIER Tools amp Supplies Needed e Blade Screwdriver e Hammer e Knife e Gloves e Eye protection e 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 Be careful of the staples 3 Using a Screwdriver and or Hammer pry off the fasteners and cut any ties holding the machine to the pallet 4 Roll the DR POWERWAGON PREMIER off the pallet Do not discard your pallet and packaging material until you are fully satisfied with your machine PN notice BE SURE TO FILL YOUR ENGINE WITH OIL AND GAS BEFORE USE SEE PAGE 11 Check the Tire Pressure The recommended tire pressures are All Terrain Tires 10 14 Ibs e Turf Tread Tires 14 28 lbs optional accessory sold separately e Swivel Tire 30 50 Ibs NOTE The heavier the load the higher the tire pressure should be Do not go above the maximum recommended load or pressure 10 DR POWERWAGON PREMIER HEN Adding Oil an
22. TO COOL AND DISCONNECT THE SPARK PLUG WIRE KEEPING IT AWAY FROM THE SPARK PLUG Regular Maintenance Checklist NOTE Consider the service intervals shown as maximum under normal operating conditions Increase the frequencies under extremely dirty or dusty conditions Procedure Before Each Use Every 25 Hours Every 100 Hours Check Operator Presence Lever A Check Engine Oil Level A Check General Equipment Condition A Lubricate Grease Fittings Check Tire Pressure A Clean Air Filter amp Precleaner Change Engine Oil 1 time 5 hours Check Parking Brake Adjustment Check Belt Tension amp Condition Check Cable Connections Clean Engine Exterior amp Cooling Fins p P P P pP Check Battery Voltage Replace Spark Plug Replace Air Filter amp Precleaner 18 DR POWERWAGON PREMIER w s GG Battery Care Proper care can extend the life of a Battery Follow these recommendations to ensure your Battery s best performance and long life e 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 e Store an unused Battery in a dry area that does not freeze e Do not charge an already charged Battery In theory you cannot overcharge our Battery with a trickle charger however when a Battery
23. TY AND THEMSELVES e YOUR DR POWERWAGON PREMIER IS NOT A PLAYTHING EXERCISE EXTREME CAUTION AT ALL TIMES THE DESIGN OF THIS MACHINE IS TO HAUL MATERIAL DO NOT USE IT FOR ANY OTHER PURPOSE e GIVE COMPLETE AND UNDIVIDED ATTENTION TO THE JOB AT HAND BEFORE YOU USE YOUR NEW MACHINE BE SURE YOU KNOW HOW TO ENGAGE THE PARKING BRAKE AND STOP THE DR POWERWAGON PREMIER AT A MOMENT S NOTICE e ALWAYS OPERATE THE DR POWERWAGON PREMIER FROM BEHIND THE HANDLEBARS NEVER FROM THE SIDE e NEVER USE THE DR POWERWAGON PREMIER TO DRAG TOW OR PUSH ITEMS e DO NOT OVERLOAD THE DR POWERWAGON PREMIER BE CAREFUL OF TOP HEAVY LOADS THE HIGHER THE LOAD THE MORE CHANCE THE MACHINE MAY TIP OVER ALSO LOADS MAY SHIFT DURING OPERATION SO TO BE SAFE SECURE YOUR LOADS AND EVEN THEM OUT WHEN POSSIBLE e THE MAXIMUM LOAD IS 500 LBS ON LEVEL TERRAIN e USE 157 GEAR WITH LOADS OVER 400 LBS EXCESSIVE SPEED BE DANGEROUS OPERATE THE MACHINE IN THE LOWEST GEAR THAT IS SATISFACTORY TO DO THE JOB e USE CAUTION WHEN MOVING DOWNHILL AND BRAKING APPLY THE PARKING BRAKE SLOWLY TO AVOID TIPPING FORWARD e WHEN SHIFTING TO REVERSE BE CAREFUL TO AVOID TIPPING AS THE SWIVEL WHEEL CHANGES DIRECTION e WATCH FOR TRAFFIC WHEN OPERATING NEAR ROADWAYS e NEVER ALLOW PEOPLE OR PETS TO RIDE IN THE DR POWERWAGON PREMIER e IF THE MACHINE SHOULD START MAKING AN UNUSUAL NOISE OR VIBRATION STOP THE ENGINE AND WAIT FIVE 5 MINUTES TO COOL VIBRATION IS GENERALLY A
24. Transaxle Arm toward the front of the machine This will put the Transmission into Reverse gear Figure 31 4 Loosen the Lock Nut on the Shift Tie Rod end with a 9 16 Open end Wrench Figure 31 and turn the Rod end clockwise to shorten the Tie Rod and counterclockwise to lengthen it Tie Rod Nut and Bolt 5 Adjust the Tie Rod length until the Shift Indicator points to a ERD Reverse when you reinstall the Tie Rod end onto the RE al Transaxle Arm 6 When the adjustment is complete re tighten the Lock Nut against the Ball end 7 Place the Tie Rod back on the Transaxle Arm insert the Bolt and re tighten the Nut This should now enable vou to use the full range of gears Transaxle Arm Forward Shift Tie Rod End Figure 31 30 DR POWERWAGON PREMIER Adjusting the Wheel Clutch 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 When properly adjusted tension on the Wheel Clutch Lever should increase when the Lever is about parallel to almost touching the Handlebar Grip Tools Needed e 2 1 2 Wrenches 1 Raise the Dump Bed to expose the Wheel Clutch Adjustment Bracket Figure 32 2 Ifthe Wheel Clutch Lever contacts the Handlebar without engaging the Wheel tighten the Clutch by loosening the Nut on the underside threaded of th
25. WARNING SIGN OF TROUBLE DISCONNECT THE SPARK PLUG WIRE AND INSPECT FOR DAMAGED PARTS CLEAN AND REPAIR AND OR REPLACE DAMAGED PARTS e BUILT IN SAFETY FEATURES SUCH AS THE OPERATOR PRESENCE SYSTEM ARE EFFECTIVE ONLY WHEN MAINTAINED AND KEPT IN PLACE e ALWAYS KEEP THE EQUIPMENT IN A GOOD SAFE OPERATING CONDITION ALWAYS MAKE CERTAIN NUTS AND BOLTS ARE TIGHT AND ALWAYS USE THE SUPPLIED SELF LOCKING HARDWARE DO NOT SUBSTITUTE USE ONLY APPROVED DR PARTS e USE THE DR POWERWAGON PREMIER ONLY IN DAYLIGHT e WHILE USING THE MACHINE DO NOT HURRY OR TAKE THINGS FOR GRANTED WHEN IN DOUBT ABOUT THE EQUIPMENT OR YOUR SURROUNDINGS STOP THE MACHINE AND TAKE THE TIME TO LOOK THINGS OVER MAKE SURE THAT YOU HAVE 100 CONTROL OF THE MACHINE AT ALL TIMES e NEVER LEAVE THE DR POWERWAGON PREMIER UNATTENDED WITH THE ENGINE RUNNING e DO NOT OPERATE THE MACHINE WHEN UNDER THE INFLUENCE OF ALCOHOL DRUGS OR MEDICATION CALL TOLL FREE 1 800 DR OWNER 7 SEE MANUFACTURER S INSTRUCTIONS FOR AND INSTALLATION OF ACCESSORIES ONLY USE ACCESSORIES APPROVED BY COUNTRY HOME PRODUCTS INC e 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 A Note To All Users Under California law and the laws of some
26. d Gasoline PNnorice 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 amp Stratton 6 25 Torque Quantum 16 22 oz 0 45 0 63L PNnorice TO GET AN ACCURATE READING WHEN CHECKING THE OIL LEVEL e THE MACHINE SHOULD BE ON A LEVEL SURFACE e THE DIPSTICK SHOULD BE SCREWED DOWN ON BRIGGS amp 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 Tool Tray the correct Fill 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 NOTE You must remove the tool tray to access the Oil and Fuel Reservoirs 1 Place the machine on a level surface and initially add 16 oz 1 2 quart of SAE 30 High Detergent oil recommended by the Engine Manufacturer and wait one minute for the oil to settle Figure 2 2 Check 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 Figure 2 3 Fill the Fuel Tank to not more than 1 4 from the bottom of the Fil
27. e Bracket by 1 8 to 1 4 and tightening the Nut on the outside against the Bracket Check the tension on the Wheel Clutch Lever and repeat the adjustment as needed 3 Ifthe Wheels engage before you activate the Lever or the Lever does not contact the Handlebar when activated reverse the adjustment in step 2 IF YOU OVER TIGHTEN THE CLUTCH THE MACHINE MAY LURCH FORWARD WHEN SHIFTING INTO GEAR USE CAUTION WHEN SHIFTING INTO GEAR Clutch Adjustment Bracket Nut Outside Figure 32 CALL TOLL FREE 1 800 DR OWNER 31 End of Season and Storage 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 Please refer to the Engine Owner s Manual for Engine specific procedures e Change the Oil this will help to eliminate sludge and acids in the Engine If your DR POWERWAGON PREMIER will be idle 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 Completely fill the tank with fresh unleaded gas and add the appropriate amount of stabilizer or gasoline additive Run the Engine for a short time to allow the additive to circulate e Remove the Spark Plug and pour about 1 ounce of motor Oil into the Cylinder Hole Replace the Plu
28. e your Engine Owner s Manual for information on cold weather starting Operating ALWAYS RELEASE THE WHEEL CLUTCH LEVER ON THE LEFT HANDLEBAR WHEN SHIFTING TO AVOID DAMAGING THE GEARS The DR POWERWAGON PREMIER 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 over smooth terrain Use 1 gear with loads over 400 Ibs and on slopes Never use your machine on slopes greater than 20 PNnorice WHEN ENGAGING REVERSE GEAR USE EXTRA CAUTION CHECK YOUR PATH AND FOOTING BEFORE ENGAGING THE WHEEL CLUTCH LEVER 1 With the Operator Presence Lever depressed Figure 4 on page 13 move the Shift Lever to the desired gear SQUEEZING THE WHEEL CLUTCH LEVER RAPIDLY WILL MAKE THE DR POWERWAGON PREMIER JUMP INTO MOTION SQUEEZE THE CLUTCH LEVER SLOWLY AND EASE THE MACHINE INTO GEAR 2 Squeeze the Wheel Clutch Lever on the left Handlebar slowly 14 DR POWERWAGON PREMIER Stopping CAREFUL WHEN TRANSPORTING HEAVY LOADS WITH YOUR DR POWERWAGON PREMIER IF YOU APPLY THE PARKING BRAKE SUDDENLY THE LOAD MAY SHIFT AND THE POWERWAGON MAY START TO TIP FORWARD BRAKE SLOWLY AND TRY TO AVOID OVERLOADING THE MOLDED BED 1 Release the Wheel Clutch Lever Figure 4 on page 13 and move the Throttle to the Idle Stop position Figure 6 on page 13 2 Setthe Parking Brake by squeezing the Parking Brake Lever on the rig
29. g and pull the Recoil Starter Rope until you feel strong resistance This will coat the Piston and seat the Valves to prevent moisture buildup e Clean and replace the Air Filter s as required e Clean dirt and debris from the Cylinder Head cooling fins Carburetor Linkage Blower Housing Rotating Screen and Muffler area of the Engine e Check to make sure the Operator Controls are moving freely Lubricate the Throttle Lever Parking Brake Lever and Key Switch with SAE 30 Oil if necessary See page 20 e You should remove the Battery and keep it in a cool dry place when the DR POWERWAGON PREMIER is in storage We suggest charging the Battery every 4 to 6 weeks while the DR is stored and again when you are ready to start the new season This will help the Battery maintain its charge all season See page 19 Recycling a Used Battery PN notice PLEASE DISPOSE OF USED BATTERIES RESPONSIBLY ACCORDING TO YOUR LOCAL HAZARDOUS MATERIALS REGULATIONS NEVER THROW AWAY USED BATTERIES IN YOUR HOUSEHOLD TRASH Please dispose of your used batteries responsibly by recycling them Call your local Solid Waste Management District or your local waste handler to locate the collection site nearest you Some collection sites recycle batteries year round others collect them periodically You can also visit the Website of Earth 911 for more information www earth911 org Once there click the Municipal HHW link under Hazardous Household Waste and enter y
30. heel Gray 16 x 6 50 8 Terr 49 106381 Key Square 3 16 x 1 1 2 50 160521 Shim 75 ID 1 0 OD 25 L 52 112371 Washer Flat 10 24 USS 53 112381 Washer Flat 1 4 USS 58 106401 Key Woodruff 3 16 x 1 2 78 165391 Anchor Wheel Drive Cable 80 110761 Nut Nylon Lock 5 16 18 84 110731 Nut Nylon Lock 1 4 20 91 111501 Screw 1 4 28 x 3 4 100 150451 Bolt HCS 5 16 18 x 1 3 4 101 123361 Bolt HCS 5 16 18 x 1 1 4 104 123211 Bolt HCS 5 16 18 x 3 4 114 160871 Coupling Shift Lever 117 160351 Tie Rod 39 09 Rod amp Ball Ends 132 111721 Screw 5 16 18 x 3 4 Tri lobe 139 108891 Transaxle Front Hanger 140 108791 Transaxle Shift Arm 141 178931 Transaxle 4 FWD I REV 144 111141 Pulley 7 0 V Belt 5 8 Bore 150 111261 Ring Retaining 3 4 type E 182 180851 Bolt HCS 1 4 20 x 2 3 4 191 129691 Shim 75 ID 1 125 OD 06 L 40 DR POWERWAGON PREMIER ERIBLINWEII IeIIIM lt I III I I I lt II I III II I IIO IIIIIGNIIZH II II IIII IK ESCT lt Z lt C gt lt CO W U IH I gt I II II lt I I lt I I lt UWIWI I IIIIII I IWKM W W IKIXWII I I lt IK IKI K G CG IN I II lt IIICOITGSSSS Schematic Main Axle Assembly HAIN FRAME LOCATION TYPICAL BOTH SIDES 01 26 2006 CALL TOLL FREE 1 800 DR OWNER 41 Parts List Molded Body Assembly NOTE Part numbers listed are available through Country Ho
31. ht Handlebar and lifting the Parking Brake Lock Figure 5 on page 13 3 Shift to N Neutral Figure 6 on page 13 4 Turn Key to the OFF position and remove it for safety PN norice IN AN EMERGENCY SITUATION RELEASING THE OPERATOR PRESENCE LEVER WILL STOP THE MACHINE AFTER THE MACHINE STOPS FOLLOW STEPS 2 THROUGH 4 ABOVE Operating Tips e Avoid abrupt start ups Always squeeze the Wheel Clutch Lever slowly to avoid bucking or tipping the DR POWERWAGON PREMIER e 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 PREMIER Loading THE RECOMMENDED MAXIMUM LOAD LIMIT FOR THE DR POWERWAGON PREMIER IS 500 LBS ON LEVEL TERRAIN AND 1 GEAR AND 400 LBS ON SLOPES NEVER OPERATE ON SLOPES GREATER THAN 20 PLACING MORE WEIGHT IN THE BED MAY DANGEROUS TO THE OPERATOR AND CAN PERMANENTLY DAMAGE THE UNIT e When loading your DR POWERWAGON PREMIER keep in mind the bulk and weight of what you will be hauling and the terrain you will be crossing e Keep the load balanced and secured Always distribute the load evenly so your DR POWERWAGON PREMIER will be as stable as possible e Don t pile material too high Divide your load and make several lighter trips Do not pile heavy loads such as rocks or gravel to a height that will make the DR POWERWAGON PREMIER top heavy and susceptible to tipping over e Be careful going downhill a
32. is fully charged and the charger is still on it generates heat that could be harmful to the Battery A fully charged Battery will read 12V 13 2V with a voltmeter e Do not continue to crank the Engine when the Battery charge is low Charging the Battery 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 Atl amp the Battery may need charging for as long as 48 hours e At2 amps the Battery may need charging for as long as 24 hours NOTE Using the Recoil Starter and then running the Engine will not recharge a dead or significantly discharged Battery To connect a battery charger to your DR POWERWAGON PREMIER follow the steps listed below 1 Detach the two 2 Battery cables going to the Battery on your machine 2 Attach the red Battery Charger Wire to the red Battery tab and the black Battery Charger Wire to the black Battery tab 3 Plug the Battery Charger into an outlet NOTE We have modified the Battery Wire Clips and Extension Tabs to accommodate different wiring connections If you need to adapt your Charger to your equipment please call one of our Technical Support Representatives for more information PN NOTICE WHEN YOU ARE FINISHED CHARGING THE BATTERY DISCONNECT THE CHARGER FROM THE
33. l Clutch Lever is released disengaged the Belt Guides will just touch the Belt Figure 19 to prevent the DR POWERWAGON PREMIER from creeping Guides are perpendicular to and n the Belt with Clutch Figure 19 CALL TOLL FREE 1 800 DR OWNER 23 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 e Blade Screwdriver e Eye protection e Pliers 1 Block the machine up off the ground so that the Front Wheels spin freely 2 Rotate the Tire so the Key slot is upward then pop off the Wheel Lock Ring with the Screwdriver Figure 20 and save it Remove the Washer and slide the Wheel off 3 replace the Wheel leave the Key in place if possible and slide the Wheel back on If the Key comes out when you take the Wheel off put the Wheel back on and rotate it until the Key slots line up Slide the Key back in place and reinstall the Washer and Wheel Lock Ring Tip Pliers will help seat the Lock Ring NOTE When replacing the Wheel Lock Ring make sure the center of the Wheel Lock Ring is opposite the Key Wheel Lock Ring Figure 20 24 DR POWERWAGON PREMIER Adjusting the Parking Brake NOTE If your DR POWERWAGON PREMIER rolls on slopes when the Parking Brake is set or if you can t get the Parki
34. l Neck with fresh unleaded gas See the Engine Manufacturer s Owner s Manual for more information Figure 2 CALL TOLL FREE 1 800 DR OWNER 11 Connect the Battery Wires Connect the red wires to each other Figure 3 The black wires were connected at the factory Red Wires Connected Made in Taiwan for Country Home Products Rechargeable Battery Figure 3 12 DR POWERWAGON PREMIER xuz CHAPTER 4 OPERATING YOUR DR POWERWAGON PREMI ER This chapter covers the procedures for starting and stopping your new DR POWERWAGON PREMIER and discusses basic operation features Before Starting the Engine Operator Presence Lever 1 Check the oil level every time you use the machine Figure 2 on page 11 Check the gas level Figure 2 on page 11 Check the tires for proper inflation Make sure to secure the Dump Latch See Set the Parking Brake by squeezing the Brake Lever Figure 5 on the right Handlebar and lift up on the Parking Brake Lock Figure 5 locking the lever in place To release the Parking Brake just squeeze the Parking Brake Lever again NOTE The DR POWERWAGON PREMIER is equipped with an Operator Presence Control for added Figure 4 safety The Operator Presence Lever must be depressed whenever the Shift Lever is in gear or the engine will stop You may run the engine without depressing the Operator Presence Lever Figure 4 only if the Shift Lever is in the N Neut
35. ley 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 Engine Owner s Manual for Engine specific procedures U U U U Check that the Key is in the RUN Position Check that the Spark Plug wire is attached Check the Operator Presence Switch connection beneath the Panel at the Key Switch Check the Operator Presence Switch connection at the Engine Check the oil and gas level See page 11 The gas may be old change it Use a fuel stabilizer if you keep gas longer than one month Check the Throttle adjustment and travel The Spark Plug may be dirty or cracked change it the Spark Plug is oily leave it out hold a rag over the Plug hole and pull the 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 CALL TOLL FREE 1 800 DR OWNER 33 WHEN PERFORMING ANY MAINTENANCE YOU MUST FIRST SHUT OFF THE ENGINE WAIT FIVE 5 MINUTES TO ALLOW PARTS TO COOL AND DISCONNECT THE SPARK PLUG WIRE KEEPING IT AWAY FROM THE SPARK PLUG SYMPTOM POSSIBLE CAUSE The Engine will not start using Electric Start Please refer to the Engine Owne
36. me Products Inc Refit Parti Description 19 109131 Bolt 5 16 18 x 1 1 2 Carriage 26 112311 Spacer 327 ID 500 OD 1 5 47 108771 Dump 48 109401 Bushing 375 ID 50 OD 1 13 L 5 112411 Washer Flat 5 16 USS 59 110211 Grip Handle 1 1 4 Black 74 110691 Nut 5 16 18 79 110751 Nut Nylon Lock 3 8 16 80 110761 Nut Nylon Lock 5 16 18 82 111081 Plug 1 x 1 OD 87 111531 Bolt HCS 3 8 16 x 2 1 4 99 111591 Bolt HCS 5 16 18 x 2 1 2 105 111411 Bolt HCS 5 16 18 x 3 128 112501 Washer Lock 5 16 155 124561 Molded Bed 34 x 44 1 2 x 9 156 110071 Frame Large Molded Bed 42 DR POWERWAGON PREMIER Schematic Molded Body Assembly CALL TOLL FREE 1 800 DR OWNER 43 05 11 2006 Notes 44 DR POWERWAGON PREMIER Daily Checklist for the POWERWAGON PREMIER 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 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 JENGINE It is very important to keep the Engine clean Remove grass and other debris from the Engine cooling fins and Debris Guard A dirty Engine retains heat and can cause damage to internal Engine components BELT Check the Drive Belt for wear proper alignme
37. nd applying the Parking Brake Squeeze the Parking Brake Lever very slowly to avoid dumping the load CALL TOLL FREE 1 800 DR OWNER 15 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 157 GEAR ON SLOPES WITH A MAXIMUM LOAD OF 400 LBS NEVER OPERATE ON SLOPES GREATER THAN 20 e Never operate the DR POWERWAGON PREMIER on slopes greater than 20 degrees Figure 8 This is for safety and proper engine operation Doing so could deprive the engine of oil and cause it to overheat resulting in component damage 7 e USE CAUTION DR POWERWAGON PREMIER may become unstable when moving over ruts bumps and other depressions e slope a heavy load will tend to shift When using your DR POWERWAGON PREMIER keep in mind that loads tend to shift to the downhill side of the dump bed Secure your load in the bed to limit the shifting of the load on slopes The higher and heavier the load the greater the Figure 8 possibility of tipping over Travel up and down slopes Figure 8 and avoid going across slopes e Again be especially careful with full loads A good rule of thumb the steeper the hill the lighter and lower your load should be e When going downhill keep a firm grip on the Handlebars and push down slightly Do not apply the Parking Brake abruptly when going downhill
38. ng Brake to set it needs to be adjusted Figure 21 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 e 1 2 Wrench or Socket 1 With the machine on a level surface set the Parking Brake 2 Putthe Transmission in N Neutral 3 Test the Parking Brake by trying to roll the machine It should not move in either direction with the Parking Brake set 4 If it does move turn the Brake Adjustment Nut on the Transaxle Figure 21 1 4 turn clockwise with a 1 2 Wrench to tighten the Parking Brake Test the Parking Brake as described in Steps 1 3 Repeat the adjustment if necessary 5 If you can t get the Parking Brake to release turn the Brake Adjustment Nut Figure 21 on the Transaxle 1 4 turn counterclockwise with a 1 2 Wrench to loosen the Parking Brake Test the Parking Brake as described in Steps 1 3 Repeat the adjustment if necessary NOTE Turn the Brake Adjustment Nut only 1 4 turn at a time and then test the Parking Brake to see if the adjustment worked If needed adjust the Nut another 1 4 turn and test again TN Brake Adjustment N 277 Figure 21 CALL TOLL FREE 1 800 DR OWNER 25 Parking Brake Cable Adjustment NOTE The Parking Brake Cable located on the right side of the machine is factory set Figure 22 If you think the
39. nt and tension AIR FILTER A clean Air Filter will mean a much easier starting and cooler running Engine Please refer to your Engine Owner s Manual for instructions on cleaning the Air Filter TIRES Check the Tires for wear and proper inflation lt b gt DR Power Equipment A division of Country Home Products 127 MEIGS ROAD P O BOX 25 VERGENNES VERMONT 05491 1 800 DR OWNER 376 9637 www dr owner com 2007 CHP Inc 223611
40. o the R reverse position To engage the drive with the engine running and after the shift lever is in ther desired gear slowly squeeze the wheel clutch lever to engage wheels and start moving Note Use extra caution when engaging reverse gear and backing up TO STOP ENGINE Release the wheel clutch lever Set brake by squeezing the lever on the right handlebar set lock shift to N neutral Turn key to OFF position Electric starting models remove key for safety BEFORE STARTING Read Operator s Manual Set brake Check gas and oil levels Check tires for proper inflation Check latch on dump body Shift transmission to neutral TO START ENGINE TO DUMP Move throttle to RUN position OFF Stand at rear of dump body On stake body model lift or remove the front panel Pull dump release lever lift dump body from rear After dumping push dump body down by hand Be sure dump release lever engoges dump locking pin completely before loading or operating further Shift transmission to N neutral If engine is cold push primer bulb on engine 3 times Turn key to START to engage the starter as soon as engine starts release the key 180531B CALL TOLL FREE 1 800 DR OWNER 3 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 SEVER
41. oss Support Handle 80 110761 Nut Nylon Lock 5 16 18 85 110971 Pin Spring 3 16 x 1 3 4 100 150451 115 108871 Lever Shift Upper 116 110221 Grip Shift Handle 161 188271 Wire Harness w Adapter 163 112051 164 112111 Cable Throttle 36 1 2 168 150491 Screw 8 32 x 1 2 170 112441 178 164961 Grip Plain 1 Handlebar 179 16495 180 180691 183 179231 184 165181 Lever 1 Brake w Lock 186 165171 Lever 1 Wheel Clutch 187 180551 Cable Wheel Clutch 190 120301 38 Screw 3 8 16 x 1 1 2 Trilobe DR POWERWAGON PREMIER Parts Not Shown 18 120 121 138 135 Safety Labels 112141 112341 111271 110151 112261 124371 127811 137581 153421 153431 153441 180451 180531 186531 Cable Tie 7 1 2 Black Tubing Shrink Push Rivet Tool Tray 1 4 Tool Tray Frame Molded Tool Tray 15 x 18 x 4 1 2 Label American Flag Label Warning Add Oil Label Check Oil Label Dump Lever Label Dump Lever Latch Label Slope Limit Label DR Logo 4 Dia Label Control Panel Label ID and Serial Number Schematic Handlebar Controls Assembly CALL TOLL FREE 1 800 DR OWNER 942 9 Parts List Main Axle Assembly NOTE Part numbers listed are available through Country Home Products Inc Refit Parti Description 03 108921 Flange Ball bearing 2 Hole 04 152171 Bearing Ball 3 4 Bore 12 151181 Bracket Brake Cable Orange 14 187631 Cable Brake PW Pro 73 1 2 37 193121 W
42. other states you are not permitted to operate an internal combustion engine using hydrocarbon fuels without an engine spark arrester This also applies to operation on US Forest Lands All DR POWERWAGON PREMIERS 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 Contact your local fire marshal or forest service for specific information in your area Additional Information and Potential Changes Country Home Products Inc reserves the right to discontinue change and improve its products at any time without notice or obligation to the purchaser The descriptions and specifications contained in this manual were in effect at printing Equipment described within this manual may be optional Some illustrations may not be applicable to your machine 8 DR POWERWAGON PREMIER CHAPTER 3 SETTING UP YOUR DR POWERWAGON PREMI ER 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 PREMIER by reviewing the picture on this page before beginning the steps outlined in this chapter DR POWERWAGON PREMIER Controls And Features Throttle Shift Lever Parking Brake Lever Key
43. our zip code The site lists recycling centers located near you For a fee you can recycle your batteries with the International Metals Reclamation Company Visit them at www inmetco com and click Services then click Battery Recycling or contact them at INMETCO PO Box 720 245 Portersville Road Ellwood City PA 16117 724 758 2800 fax 724 758 2845 To learn more about hazardous waste recycling visit the Website for Battery Council International www batterycouncil org or for the Environmental Protection Agency www epa gov 32 DR POWERWAGON PREMIER CHAPTER 6 TROUBLESHOOTING Most problems are easy to fix Consult the Troubleshooting Table for common problems and their solutions Ifyou 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 SYMPTOM POSSIBLE CAUSE Recoil will not pull out or is difficult to pull gt gt Check the Engine oil level the Engine may be seized There may be an oil compression lock in the cylinder Take out the Spark Plug hold a rag over the Spark Plug hole and pull the Recoil Cord several times to blow out any oil in the cylinder Wipe off the Spark Plug and reinstall it Try to turn the Engine pul
44. r s Manual for Engine specific procedures gt gt Check all the items under the section called Electric Starting on page 13 Check the previous section The Engine will not start manually on page 33 for possible causes Check the wire connections especially the ground connection the large black wire coming from the Battery where it connects to the Engine Check the wire connections to the Solenoid Disconnect the black Battery ground wire first to avoid sparks Check to be sure that all of the connections are clean and tight Reconnect the Battery ground wire Check the ground connection on the Solenoid where it bolts to the frame Using a Wrench or Socket tighten the bolts to ensure a good connection to the frame The Battery may not be charged Check the voltage yourself or at a gas station If it is low charge it with a 12 volt 1 to 2 amp trickle charger If you do not use your machine for at least 45 minutes at a time the Battery may need to be periodically charged See the Battery Care section on page 19 If the Battery is charged and your DR POWERWAGON PREMIER still will 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 U U Check the Throttle travel and adjustment The Air Filter may be dirty change it following the procedure in the Engine Owner s Man
45. ral position Figure 6 Parking Electric Starting Brake Lever 1 Move the Shift Lever to the N Neutral position Parking Brake Figure 6 Lock 2 Move the Throttle to the RUN position Figure 5 3 If the engine is cold depress the Primer Bulb three 3 times Figure 7 on page 14 In cold weather you may need to depress additional times being sure that the Bulb inflates between pumps 4 Turn the Key to the START position Figure 6 As soon as the engine starts release the Key and it will return to the RUN position 5 Move the Throttle to the desired Engine speed NOTE See your Engine Owner s Manual for information on cold weather starting Figure 6 CALL TOLL FREE 1 800 DR OWNER 13 Manual Recoil Starting 1 Move the Shift Lever to the N Neutral position Figure 6 on page 13 2 Move the Throttle Lever to the RUN position 3 If the engine is cold depress the Primer Bulb three 3 times Figure 7 In cold weather you may need to depress additional times being sure that the Bulb inflates between pumps 4 Turn the Key the RUN position Figure 6 on page 13 5 Pull the Recoil Pull Handle slowly until you feel resistance then pull the Handle with a rapid full arm stroke to overcome compression and start the Figure 7 engine Repeat if necessary Primer Bulb 6 After the engine starts move the Throttle Lever Figure 6 on page 13 to the desired Engine speed NOTE Se
46. rmation CALL TOLL FREE 1 800 DR OWNER 1 CHAPTER 2 GENERAL SAFETY RULES READ THIS SAFETY amp OPERATING INSTRUCTIONS MANUAL BEFORE YOU USE THE DR POWERWAGON PREMIER BECOME FAMILIAR WITH THE SERVICE RECOMMENDATIONS TO ENSURE THE BEST PERFORMANCE FROM YOUR MACHINE Labels Your DR POWERWAGON PREMIER carries prominent labels as reminders for its proper and safe use Shown below are copies of all the labels that appear on the equipment Take a moment to study them and make a note of their location on your DR POWERWAGON PREMIER as you assemble and before you operate the machine Replace damaged or missing safety and information labels immediately WARNING Check Oil WARNING Add Oil Before Starting Engine Before Starting Engine 137581 127811 Make sure you add oil before starting the engine the unit is shipped without oil Fill the oil reservoir slowly to make sure you don t overfill it 153421 2 DR POWERWAGON PREMIER EE DO NOT OPERATE POWERWAGON ON SLOPES GREATER THAN 20 DEGREES 153441 BE SURE DUMP EVER IS SECUREL LATCHED BEFORE LOADING OR OPERATING POWERWAGON 153431 TO OPERATE Release parking brake Shift transmission into desired gear by positioning the pin on the lever next to the desired gear Use 1st gear for loads over 300 pounds and whenever you need more power or more control of the bed Limit loads to less than 400 pounds on slopes To shift into reverse pull shift lever back t
47. ual The Spark Plug may be dirty or cracked change it If the Spark Plug is oily leave it out hold a rag over the Plug hole and pull the Recoil cord several times to blow out any oil in the cylinder then wipe off the Plug and reinsert it The gas may be old change it Use a fuel stabilizer if you keep gas longer than one month The Engine may not have the right amount of clean oil If it is dirty change it following the procedure on page 21 If the Engine still lacks power call 1 800 DR OWNER 376 9637 for assistance Engine smokes y Uy U gt gt Check the oil level and adjust as needed You may be operating the machine on too great an incline See the Slopes and Uneven Terrain section on page 16 Check the Air Filter and clean or replace if needed You may be using the wrong oil too light for the temperature Refer to the Engine Owner s Manual for detailed information Clean the Engine cooling fins and the carburetor housing if they are dirty If the Engine still smokes call 1 800 DR OWNER 376 9637 for assistance 34 DR POWERWAGON PREMIER nm WHEN PERFORMING ANY MAINTENANCE YOU MUST FIRST SHUT OFF THE ENGINE WAIT FIVE 5 MINUTES TO ALLOW PARTS TO COOL AND DISCONNECT THE SPARK PLUG WIRE KEEPING IT AWAY FROM THE SPARK PLUG SYMPTOM POSSIBLE CAUSE The Belt frays or There may be a nick in a Pulley groove Check the
Download Pdf Manuals
Related Search