Country Home Products SUBURBANTM User's Manual
Contents
1. Screw Self tap for Sides 12 x 1 1 2 Caster Wheel 410 350 x 4 Shift Lever Arm Pulley Flat 2 1 4 Flat Bed Frame Flat Bed Pin 8 Flat Bed Pin 12 Bolt 1 4 x 20 x 3 4 T Nut for Latch Hook 1 4 x 20 Frame for Molded Body Main Frame Handlebar Handlebar Mount amp Body Support Brake Bracket Control Panel Differential V Belt Pulley amp Centrifugal Clutch Pulley 6 5 8 incl Set Screw 5 16 x 1 4 V Belt 38 4L380 Drive Chain 41 w Link 41 Drive Chain Master Link Drive Chain Sprocket 40 Tooth Drive Chain Idler 10 Tooth POWERWAGON Safety amp Operating Instructions Ref 72 73 75 76 77 78 79 80 81 82 83 84 85 86 87 88 91 92 93 97 98 99 100 101 103 105 106 112061 112051 109461 111611 111341 110201 124341 124331 112481 127371 109841 111311 110191 105031 111871 109281 132341 106381 110591 111901 109641 109651 110391 111941 111631 111731 Description Key Switch w Hardware amp Key for Recoil Start Key Switch w Hardware amp Key for Electric Start Throttle Cable Screw 3 8 x 2 3 4 Screw 7 16 Fine x 3 4 Gear Box Transmission 4 5 HP Centura E S Engine 4 5 HP Centura Manual Start Engine Star Lock Washer 1 4 Decal for Control Panel Decal for Shift Gate Shift Tie Rod Shift Gate Shift Lever One Piece Spacer 1 4 x 1 Throttle Spring Bracket Cap Screw 5 16 x 2 Flat Key 3 162. Sq x 1 1 2 41Drive Chain Half Link Spacer for Belt Idler 3 8 x 1 Flexible Conduit Black 1 4 ID 30 per Split Flexible Conduit 7 16 40 per Wire Harness for Manual Starting Model Throttle Return Spring Screw for Throttle Handle 10 32 x 1 1 2 Thread Rolling Screw 5 16 x 1 2 Ref 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 124 130 131 132 133 135 136 137 138 139 140 141 DR POWERWAGON Safety amp Operating Instructions Part 112431 110421 112171 112031 109381 109361 109481 109491 112361 110441 109261 109231 110271 129331 111511 110731 123401 111241 111891 111881 111491 110691 112501 112521 112391 109321 109331 Description Lock Washer 5 16 split Wire Harness for Electric Starting Model 110291 Dump Handle A T Tire Wheel 13 x 500 6 Support for Bed Frames Bed Support Pivot Bushing Bumper Strip Flat Bed 1 1 2 x 7 1 2 Cap for 1 Round Tubing Cap for 3 4 Round Tubing Wheel 13 x 5 00 6 Turf Tire Latch Hook Latch Hook Bracket Chain Tension Bracket Chain Guard Large Molded Body 3 8 x 1 1 2 Large Bolt 1 4 x 2 1 2 Cap Screw Air Filter Centura Engine Snap Ring 5 8 Short Diameter 1 x 3 4 ID 1 OD Axle Spacer 1 1 4 x 3 4 ID 1 OD Axle Spacer 1 4 x 1 Cap Screw 5 16 18 Nut 5 16 Star Lock Washer Nylon Shim Washer 3 8 Flat Washer Rubber Bumper Bumper Mount Screw 21 Main Frame
3. in the bracket Simply pushing the dump body back into place will not make it latch For safety reasons the DR POWERWAGON body is designed to not dump automatically once the dump latch is released You must lift the dump handle or the back of the body to cause it to tilt forward Figure 13 DR POWERWAGON Safety amp Operating Instructions 7 Because of the way the DR POWERWAGON body is balanced you may find that you won t be able to lift the body to dump it if you are carrying a very heavy load In this case you ll need to manually unload part of what you are hauling from the back of the bed until the load is light enough to allow the bed to tilt forward POT when you lift up on the dump handle or back of the body If you have the wooden stake body you can remove the front panel for easy dumping See page 9 for more information on using the optional stake body Figure 14 Changing Bodies If you ve purchased the optional stake body with your DR POWERWAGON you ll find it s quite simple to change bodies To change from the molded body to the stake body you simply release the dump latch tilt the molded body forward and lift it off the mainframe Allow the pivot bushings to slide out of the pivot brackets as you lift the body up Figure 15 When placing the stake body on the frame set the pivot bushings into the brackets and slide the body in place Be sure the dump latch is secure before operati
4. Assembly igure 35 DR POWERWAGON Safety amp Operating Instructions Handlebar Controls Assembly Figure 35 DR POWERWAGON Safety amp Operating Instructions 23 Assembly Figure 36 24 DR POWERWAGON Safety amp Operating Instructions Molded Body Assembly Figure 37 DR POWERWAGON Safety amp Operating Instructions 25 Stake Body Assembly 20 Figure 38 DR POWERWAGON Safety amp Operating Instructions Notes DR POWERWAGON Safety amp Operating Instructions 27 Notes 28 DR POWERWAGON Safety amp Operating Instructions Daily Check List for the DR POWERWAGON gt A WARNING Always disconnect the spark plug wire before servicing your machine OIL With the POWERWAGON level surface lift the dump body remove the oil fill cap and check the oil level Fill the reservoir with SAE30 detergent motor oil Be sure to check the dipstick as you fill and do not overfill GAS Fill the gas tank with clean fresh unleaded gasoline If the gas in the machine is more than 30 days old drain and replace it TIRES Check the tires for wear and proper inflation See the chart on page 2 for proper air pressure v AIR FILTER A clean air filter will mean a much easier starting and cooler running engine Please refer to your engine manufacturer s owner s manual for instructions on cleaning and or replacing the air filter v ENGINE It is very importa
5. Connect Battery Wires Figure 3 Fill the Machine with Oil and Gas 1 Put the recommended amount of SAE30 detergent oil into the oil reservoir Figure 4 Fill the oil to the level indicated on the dipstick Note There may be some oil in the reservoir from factory testing Check the dipstick frequently as you fill to avoid overfilling Please refer to your engine manufacturer s owner s manual for more detailed oil information 2 Fill the gas tank Figure 4 with fresh Oil Reservoir unleaded gas to within 1 4 of the top to allow for fuel expansion Please refer to your engine manufacturer s owner s manual for more specific fuel recommendations Figure 4 Check the Tire Pressure Recommended tire pressures are listed below Tire Pressure Standard Tires 14 20 16 psi All Terrain Tires 14 20 Ibs psi Caster Wheel 50 Ibs psi Please Note The heavier the load the higher the tire pressure should be However do not exceed the maximum recommended load or pressure Figure 5 2 POWERWAGON Safety amp Operating Instructions Controls amp Features 7 Parking Brake Dump Shift Lever Handle Key Switch Recoil Starter Key Switch Throttle Control Brake Control Lever Tee Lever Shift Lever Dump Latch see inset Recoil Starter see inset Dump Handle see inset Engine Gas amp Oil Fills Below Molded Body Battery Electric Starting
6. to your engine manufacturer s owner s manual Cleaning Replacing the Cartridge Air Cleaner Please refer to your engine manufacturer s owner s manual Cleaning the Static Guard amp Cooling System Please refer to your engine manufacturer s owner s manual Cleaning Replacing the Spark Plug Please refer to your engine manufacturer s owner s manual DR POWERWAGON Safety amp Operating Instructions 11 Lubrication Tools amp Supplies Needed e flexible hose grease gun e lithium grease e FLUID FILM or similar lubricant WARNING Always disconnect the spark plug wire before servicing your machine 1 There is a grease zerk above the caster wheel Figure 22 Grease it occasionally to keep the caster swiveling freely Grease Zerk Figure 22 2 There is also a grease zerk on the caster wheel Figure 23 Grease it occasionally to keep the wheel spinning freely Grease Zerk Figure 23 12 POWERWAGON Safety amp Operating Instructions 3 Lubricate the upper brake cable with FLUID FILM or similar lubricant Figure 24 Lubricate Upper Brake Cable Fi 4 Lubricate the lower brake cable with FLUID FILM or similar lubricant Figure 25 The lower brake cable is located on the right side of the machine just behind the front wheel Figure 25 5 Lubricate the throttle cable with FLUID FILM or similar lubricant Figure 26 7 Lubricate Throttle Cable The throttle cable is lo
7. DR POWERWAGON Safety amp Operating Instructions Model SUBURBAN These Safety amp Operating Instructions as well as the engine manufacturer s owner s manual contain important information concerning safety operating procedures maintenance troubleshooting and assembly tips Everyone who operates the DR POWERWAGON should read these instructions and be thoroughly familiar with them THANK Yor congratulations on your purchase of new DR POWERWAGON We have done our utmost to ensure that your POWERWAGON will be one of the most trouble free and satisfying pieces of equipment you have ever owned Please let us know of any questions or problems you may have We want to answer or correct them as quickly as possible When you do call or write please have your serial number and or order number handy it will speed things up We also hope to hear from you on how much you like your new helper And please tell your friends about your new DR POWERWAGON 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 COUNTRY HOME PRODUCTS Safety Information We want you to enjoy years of productive use from your POWERWAGON We don t want you to get injured so please take a few moments to read the following guidelin
8. LEASE SEE ENGINE MANUFACTURER S OWNER S MANUAL CLEANING THE STATIC GUARD amp COOLING SYSTEM PLEASE SEE ENGINE MANUFACTURER S OWNER S MANUAL CLEANING REPLACING THE SPARK PLUG eee PLEASE SEE ENGINE MANUFACTURER S OWNER S MANUAL TSUBRICATION 3 12 ADJUSTING tete ect ra i im II Peete v a oie pee ER IRE Pe epo eR Sie 14 REPLACING THE BRAKE PADS ee 15 REMOVING THE FRONT WHEELS ee 16 ADJUSTING THE SHIFT LEVER ee 16 END OF SEASON amp STORAGE 17 FROUBLESHOO TING sacs sicsicdsccsiesteccocenseccesacesesvcvocescede soovensaccscestesonsendescoseece sosueadescescnteseesande seseecke Eae Ee aee osio 18 I HMNEEBKIM U 20 MAIN FRAME ASSEMBLY Cea arva a ovs Pu daa aee Vo Vo Ce oa euo 22 HANDLEBAR CONTROES ASSEMBLY TR URN UR Po ee S Re PE E ee CH subse PE Re eS Tu 23 AXLE ASSEMBLY enis esceeesnees secUeen ven vL ERES Re UY is talsedeceaceasetussssvens E 24 MOLDED BODY ASSEMBLY 5 6 catesssesscdsoncevaseses un eee P peu SEPT USE Ye 25 STAKE BODY ASSEMBLY eccentric nai oae Ua Poe ex oq auae du aar era reae ee Duae 26 DAILY CHECK LIST FOR THE DR POWERWAGON seesssssssssssssssssssssssssssssssssssssss
9. Models Not Shown Turf Tread Tires Figure 6 DR POWERWAGON Safety amp Operating Instructions Starting amp Operating Before Starting Check gas levels Check the tires for proper inflation Check the latch on the dump body it should be secure Set the parking brake Shift the transmission to neutral Electric Starting 1 When starting a cold engine push the primer bulb Figure 7 firmly at least three times allowing the bulb to return completely to its original position between pushes Note Do not use the primer when restarting a warm engine 2 Turn the key Figure 8 past the START position to engage the starter As soon as the engine starts release the key If the engine doesn t start repeat priming and try again Note Holding the throttle control lever at half throttle may help with starting Brake ce Throttle If the engine won t start with the key the Control Control battery may need to be charged Please see Lever page 10 for information on battery care and maintenance Your engine is also equipped with a manual recoil starter Please see the instructions i M below Parking 3 Dump Latch Brake Dum Shift Lever Manual Recoil Starting used for both Electric and Manual Key Switch Starting models Recoil Starter Figure 8 1 When starting a cold engine push the primer bulb Figure 7 firmly at least three times allo
10. RWAGON during the daylight hours Always operate the DR POWERWAGON from behind the handlebars never from the side Operating the DR POWERWAGON in wet grass could increase the danger of your slipping falling and being injured Use extra CAUTION in wet areas When operating over uneven terrain and slopes use EXTREME CAUTION and make sure of solid and firm footing at all times THINK SAFETY Loads should be less than 300 pounds on slopes The steeper the slope the lighter the load Never allow children to operate the POWERWAGON Never carry children adults or pets in the body of the DR POWERWAGON Give complete and undivided attention to the job at hand and be sure you know how to stop the DR POWERWAGON at a moment s notice Use caution when another person approaches Keep hands away from belts and pulleys when the engine is running DR POWERWAGON Safety amp Operating Instructions 1 DO NOT OVERLOAD THE DR POWERWAGON Loads should be less than 400 pounds on the level and 300 pounds on slopes Be careful of top heavy loads especially in the back corners of the molded body The higher the load the more chance the machine may tip Also loads may shift during operation so even out loads when possible to be safe When shifting to reverse be careful of tipping as the caster wheel changes direction Don t rev the engine Excessive speed or tampering with the governor can be dangerous Operate the engine at the slow
11. Running the DR POWERWAGON recharges the battery See page 10 for more battery care information Uneven Terrain amp Slopes Exercise caution when using the DR POWERWAGON on uneven terrain or slopes A good rule of thumb the steeper the hill the lighter and lower your load should be Limit loads to less than 300 pounds on slopes Use a first gear and move slowly if the ground is rough especially with a full load Be sure you re in low gear before starting down a slope Shifting mid slope can be awkward We do not recommend using the DR POWERWAGON for continuous use on a slope greater than 20 degrees Doing so may deprive the engine of oil and damage the engine components For added traction when going uphill lift up on the handlebars slightly to transfer weight to the front wheels and improve traction When going downhill keep a firm grip on the handlebars and push down slightly Do not apply the brake abruptly when going down hill with a heavy load or the DR POWERWAGON may pitch forward on its front end We recommend going straight up and down slopes instead of across them whenever possible If you do maneuver across a slope use EXTREME CAUTION as this puts additional pressure on the downhill side of the machine The higher and heavier the load the greater the chance the DR POWERWAGON may tip over Limit side hill loads to less than 300 pounds Be careful with partial loads Material can shift within the body an
12. ate to the front Reinstall the two caliper bolts being careful not to over tighten them 5 Test the brake With the machine ona level surface set the parking brake and put the machine in neutral If the brake does not engage or hold tighten the brake adjustment nut 1 4 turn with a 1 2 wrench see page 14 Figure 31 Note Check the parking brake periodically and adjust as needed DR POWERWAGON Safety amp Operating Instructions 15 Removing the Front Wheels Tools amp Supplies Needed 2 7 16 wrenches block to raise machine off ground AX WARNING Always disconnect the spark plug wire before servicing your machine 1 Block the machine so the wheel is an inch or two off the ground 2 Using 2 7 16 wrenches loosen the bolt Figure 32 and slide the wheel off the axle Figure 32 Adjusting the Shift Lever If you are unable to shift into reverse or 2nd gear the shift lever and tie rod need to be adjusted Tools needed 2 1 2 open end adjustable or socket wrenches AX WARNING Always disconnect the spark plug wire before servicing your machine 1 Remove the dump body 2 Move the shift lever into the reverse position 3 Loosen and remove the tie rod nut and bolt from the transmission arm Figure 33 Unhook the tie rod from the transmission arm 4 Fully extend the transmission arm toward the rear of the DR POWERWAGON this will put it in reverse gear 5 Loosen the l
13. cated on the right side of the machine just above the primer bulb Figure 26 DR POWERWAGON Safety amp Operating Instructions 13 Adjusting the Brake If the DR POWERWAGON rolls on slopes when the parking brake is set or you can t get the parking brake to set the brake needs to be adjusted Tool Needed 1 2 wrench Brake Assembly WARNING Always disconnect the spark plug wire before servicing your machine 1 With the machine on a level surface set the parking brake 2 Putthe transmission in Neutral 3 Test the brake Try to roll the machine It should not move forward or back with the parking brake set 4 Ifthe machine does move turn the nut on the transaxle Figures 27 amp 28 1 4 turn Figure 27 clockwise to tighten the brake Repeat Steps 1 3 and readjust if needed ee Adjust Nut to Loosen or Tighten Brake Note Turn the nut only 1 4 turn at a time then test the brake to see if further adjustment is needed If you can t get the parking brake to release turn the nut on the transaxle Figures 27 amp 28 1 4 turn counterclockwise to loosen the brake Repeat Steps 1 3 and readjust if needed Figure 28 Brake Cable Adjustment The brake cable is factory set Figure 29 If you think the brake cable needs to be adjusted you may actually need to replace the brake pads Please see page 15 for instructions Brake Cable Ips Figure 29 14 DR POWERWAGON Safe
14. d tip the machine 6 DR POWERWAGON Safety amp Operating Instructions Loading Ay WARNING The recommended load limit for the DRE POWERWAGON is 400 Ibs on level ground and 300 pounds on slopes Placing more weight in the body may be dangerous and can permanently damage the machine Please follow these important guidelines when loading your DRP POWERWAGON Always distribute the load evenly so that your DR POWERWAGON will be as stable as possible Figure 12 Do not pile heavy loads such as rocks or gravel to a height that will make the DR POWERWAGON top heavy and susceptible to tipping over Keep the load balanced and don t pile material too high in the front or back corners of the molded body Instead take the time to divide your load and make several lighter trips On a slope a heavy load will tend to shift to the downhill side of the body Again it is safer to make several smaller lighter trips Reminder The gas fill is located below the dump body Plan your work accordingly so you won t run out of gas with a full load Dumping To dump stand at the rear of the machine and unlatch the dump body from the bracket Figure 13 Pull up on the dump handle or the back of the body to tip it forward Figure 14 After unloading push the dump body back down into place by hand Be sure the latch fits securely into the bracket on the dump body Note You must lift the latch handle and position it
15. der head cooling fins blower housing debris screen and muffler area of the engine Please refer to your engine manufacturer s owner s manual for additional information If your machine is electric starting store the battery in a dry area that does not freeze When storing the machine with the battery mounted we recommend disconnecting the red wire between the battery and the wiring harness for safety and to prevent accidental discharge of the battery If the machine is not used over a long period the battery should be charged every four to six weeks See page 10 Check to make sure that the operator controls are moving freely Lubricate them with FLUID FILM or similar lubricant if necessary DR POWERWAGON Safety amp Operating Instructions 17 Troubleshooting WARNING Always disconnect the spark plug wire before servicing your machine Please refer to your engine manufacturer s owner s manual for additional engine troubleshooting information Engine Engine won t start C Check for adequate fresh fuel Also check to see that the fuel line isn t obstructed and that the air cleaner is free of dirt and debris c If the Electric Starting Model won t start with the key try starting the engine with the recoil starter If the engine starts the battery may simply be low on charge it could be dead or a connection may be loose See below for battery maintenance Also check the wiring connections to the battery c The spar
16. e alternator should be checked with a fully charged battery and should put out 12 to 13 5 volts 1 5 to 2 amps Shifting Won t shift into reverse or high gears c Shift lever needs adjusting Adjust tie rod eye bolt Please see page 16 for additional information Wheels Lacks traction C Try to even out load and add more weight to bed c Lift up slightly on the handlebars to transfer weight to the front wheels Dump Bed Unable to dump load C You may need to manually unload part of what you are hauling from back of dump bed until load is light enough to allow bed to tiltl forward when you lift up on back of it Please see page 7for additional information DR POWERWAGON Safety amp Operating Instructions 19 Parts List Please refer to the numbered drawings on pages 22 26 Note Not all parts numbers listed appear on the drawings Ref oa Oo 11 12 13 14 15 16 17 18 19 20 21 23 24 25 26 27 28 29 30 31 32 33 34 35 36 20 Part 108921 108931 131191 135101 113051 109041 109071 110051 112141 109131 110281 109441 109591 110891 110921 109371 110491 112411 112371 112381 109831 110251 110211 109241 110731 110681 110231 110761 110781 110751 110571 111081 109251 111281 110971 Description Ball Bearing 2 Hole Flanges Ball Bearing 3 4 Bore Battery Electric Starting Battery Clamp Elect
17. ease the throttle lever then move the shift Shift Lever lever to the right and all the way backwards Engaging the Drive With the engine running slowly squeeze the ALY URR 2 throttle lever on the right handlebar until you lg reach desired speed n i 4 Note Squeezing the throttle lever quickly will E make the DR POWERWAGON jump forward Squeeze the throttle lever slowly and ease the machine into gear When engaging reverse USE EXTRA CAUTION Check to see that there are no obstacles behind you Figure 10 and use a slow throttle setting with heavy loads to avoid abrupt lifting of the handlebars and tipping As ave e 2 Aa A s T3 AN OLBIA us ni NP Y E gt A zi SS T AE ef A 9 C oom Pr B Figure 10 DR POWERWAGON Safety amp Operating Instructions Operating Tips When the throttle is not engaged the machine will act like it s in neutral it will freewheel even if it s in gear Always have the throttle engaged or the brake on for control You can leave the machine in gear while idling but always use the parking brake and never leave the machine unattended while running If you re making frequent stops to load and unload it is better to leave the DR POWERWAGON running on idle with the parking brake on than to start and stop repeatedly Frequent starting and stopping will reduce the life of the battery
18. er Service Department with well trained and friendly folks whose sole job it is to ensure that you get any help you need parts that need to be replaced or questions answered courteously and as promptly as possible For future reference when dealing with your warranty save the packing list from the outside of the DR POWERWAGON box and keep it in a safe place Also please fill out the information below Name Purchased Under Order Number Serial Number Date Purchased DR POWERWAGON Safety amp Operating Instructions iii Table of Contents SAFETY INFORMATION I TRESS APPROPRIATELY ci tend 1 PREPARATION ccce ccr A E E cub rec is I OPERATING EHE MACHINE S AEBLY I WARNING TO ALL CALIFORNIA AND OTHER USERS ee II ASSEMBLY ar crE 1 INSTALE THE UPPER HANDLEBAR S heietan tod ertt coe te eto Fe Pee oe pe CNN AN e uen Ve ve Ehe aoo deae uve Cha aUe vv Ee Fe e a Re Fe eua rena 1 CONNECT THE BATTERY WIRES be ue Dee 2 FIEL THE MACHINE WITH OIL AND GAS 2 CHECK THE TIRE PRESSURE ee 2 CONTROLS amp FEATURES suseoesesconse sev eU NEUE e NN TR 3 STARTING amp OPERATING esissscsssiesssscesosccicstetesssevasessessesesa
19. es for safely operating your new machine Dress Appropriately Wear shoes with non slip treads when using your DR POWERWAGON If you have safety shoes we recommend that you wear them Do not use the machine while barefoot or wearing open sandals e Use ear muffs or ear plugs to protect your valuable hearing Wear gloves to protect your hands as well as to provide additional comfort and support Preparation Read these Safety amp Operating Instructions as well as the engine manufacturer s owner s manual before you use the DR POWERWAGON Become familiar with the controls engine and service recommendations to ensure the best performance from your machine Inspect the area you ll be working in BEFORE using DR POWERWAGON Remove any obstacles and avoid areas with poor footing Be sure the machine is in NEUTRAL and the brake is set before attempting to start the engine Fill the gasoline tank outdoors Avoid spilling gasoline and don t fill the tank while the engine is running or if you are smoking Remember The gas fill on the DR POWERWAGON is located beneath the dump body Keep this in mind as you work to avoid running out of gas with a full load On average the DR POWERWAGON will run continuously for about 45 minutes This running time will vary depending on the speeds used loads carried and terrain covered Operating the Machine Safely Unless there is very good artificial light only use the POWE
20. est speed that is satisfactory for the task at hand While using the DR POWERWAGON don t hurry or take things for granted When in doubt about the equipment or surroundings stop the machine and take time to look things over Make sure you have 100 control of the machine at all times Built in safety features are effective only when maintained and kept in place DO NOT under any conditions remove cut bend weld or change standard parts on the DR POWERWAGON A change made on your own can make the equipment unsafe and may void your warranty Some state and local regulations require the use of a spark arrester on gasoline powered engines Contact your local fire marshal or forest service for specific information pertaining to your area If you are required to use a spark arrester please contact one of our Customer Service Representatives TOLL FREE 1 800 DR OWNER 376 9637 for assistance in obtaining and installing one Warning to California and Other Users Under California law and the laws of some other states you are not permitted to operate an internal combustion engine using hydrocarbon fuels without an engine spark arrester All DR POWERWAGONS 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 y
21. he spark plug wire and mount it on the retaining post Figures 20 amp 21 Spark Plug Disconnected and Mounted on the Retaining Post Spark Plug Connected Figure 20 Figure 21 Battery Electric Starting Models Proper care can lengthen the life of a battery Follow these recommendations to ensure your battery s best performance and long life Do not allow the battery charge to get too low If the machine is not used the battery should be charged at least every four to six weeks Store an unused battery in a dry area that does not freeze Do not charge an already charged battery In theory our battery cannot be overcharged with a trickle charger however when a battery is fully charged and plugged into a charger it generates heat that could be harmful to the battery A fully charged battery will read 12 5V 13 5VDC with a voltmeter Do not continue to crank your engine with a low battery 10 DR POWERWAGON Safety amp Operating Instructions Charging the Battery If the battery loses its charge you ll 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 e Atlamp the battery may need to be charged for as much as 48 hours e At2amps the battery may need to be charged for as much as 24 hours Note Using the recoil starter and then running the engine will not recharge a dead battery Changing the Oil Please refer
22. k plug may be fouled In this case replace it See your engine manufacturer s owner s manual for more information Engine lacks power Check to make sure that your engine has proper the amount of oil 5 5 Check the air intake holes on top of the engine They should be free and clear of debris If they get clogged the engine may be damaged by overheating C Check the air cleaner and carburetor as described in your engine manufacturer s owner s manual If the carburetor needs adjusting call us at 1 800 DR OWNER 376 9637 so we can recommend a DR Friendly Service Center in your area Battery Engine won t start with key c If the Electric Start model won t start with the key try starting the engine with the recoil starter If the engine starts the battery may need to be charged C A connection may be loose Check the wiring connections to the battery Battery is low on charge C The battery may need to be charged Please see page 10 for more information If your battery still does not hold a charge please contact us and we will arrange to have a new one shipped to you Batteries covered under the 1 Year Warranty will be replaced free of charge see Parts Order Form in your Product Package or call for ordering information 18 DR POWERWAGON Safety amp Operating Instructions Alternator isn t recharging the battery gt Have alternator checked by an authorized engine service center Th
23. ng the machine Figure 15 8 POWERWAGON Safety amp Operating Instructions Using the Optional Stake Body Removing the front panel for easier dumping When moving loose materials such as gravel mulch and topsoil simply lift and remove the front panel of the stake body for easier dumping Figure 16 Removing the front and side panels for oversized loads For oversized loads such as fencing gardening tools tree limbs rocks etc you can remove the front and two side panels on the stake body Figure 17 Reversing the front panel for controlled dumping If you re spreading gravel or mulch over a large area you can reverse the front panel of the stake body for more controlled dumping Lift and remove the front panel turn it around and mount it backwards Then raise or lower it depending on how much material you want to spread as you move Figures 18 amp 19 Figure n DR POWERWAGON Safety amp Operating Instructions 9 Maintenance For Engine Maintenance Please Refer to the Engine Manufacturer s Owner s Manual Regular maintenance is the way to ensure the best performance from your machine Follow the instructions below and those in the engine manufacturer s owner s manual to keep your DR POWERWAGON in top condition Always Remove the Spark Plug Wire Before Doing Any Adjustments or Maintenance Before doing any adjustments or maintenance on your DR POWERWAGON you should always disconnect t
24. nt to keep the engine clean Remove debris and other build up from the engine cooling fins and brush off any chaff from the recoil start debris guard as you use your DR POWERWAGON A dirty engine retains heat and can cause damage to the internal engine parts Please refer to your engine manufacturer s owner s manual for further instructions on cleaning the engine parts COUNTRY HOME PRODUCTS Meigs Road P O Box 25 Vergennes Vermont 0549 1 800 DR OWNER 376 9637 1999 CHP Inc 138121
25. ock nut on the eye bolt Figure 34 and turn the eye bolt one turn at a time to take up slack in the tie rod Place the tie rod back on the transmission arm insert the nut and bolt and retighten This should enable you to engage the full L 4 Was R range of gears Loosen Lock Nut on Eye Bolt f Figure 34 16 POWERWAGON Safety amp Operating Instructions End of Season amp Storage A WARNING Always disconnect the spark plug wire before servicing your machine Please refer to your engine manufacturer s owner s manual for engine specific procedures If your DR POWERWAGON will be idle for more than 30 days we recommend using a gas stabilizer This will prevent the carburetor from gumming up Inspect the gas tank If there is dirt or moisture in the gas 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 Change the oil Please refer to your engine manufacturer s owner s manual for additional information Remove the spark plug and pour about 1 ounce of motor oil into the cylinder hole Pull the recoil starter rope until you feel strong resistance This will coat the piston and seat the valves to prevent moisture buildup Replace the air filters Please refer to your engine manufacturer s owner s manual for additional information Clean dirt and debris from the cylin
26. our local fire marshal or forest service for specific information in your area ii DR POWERWAGON Safety amp Operating Instructions We Want You to be Totally Satisfied The DR POWERWAGON is designed to provide year after year of trouble free performance To ensure that you are totally satisfied with this important purchase we offer the following three part Assurance of Satisfaction DR POWERWAGON is GUARANTEED FOR ONE FULL YEAR against defects in materials and workmanship in consumer use In rental and commercial use the machine is guaranteed for 90 days If you believe that a part is defective please write or call us immediately We will do our best to remedy the problem including repairing or replacing defective parts as quickly as possible The engine and transmission are guaranteed separately by the manufacturers for two years in consumer use and 1 year in commercial use IF WITHIN THE FIRST 30 DAYS of actual hands on use you have questions or you are less than 100 satisfied with your DR POWERWAGON please write or call us at 1 800 DR OWNER 376 9637 We ll do everything possible to answer your questions or make things right even if it means that you return your DR POWERWAGON for a full refund of its purchase price shipping costs included Refund on shipping is for standard method and applies to the contiguous United States U S Territories and Canada only We operate for our Owners a 7 Day a Week Custom
27. ric Starting Battery Pad Electric Starting Boards 5 4 x 4 Boards 5 4 x 6 5 8 Plywood PT Cable Tie Carriage Bolt 5 16 x 1 1 2 Brake Handle Brake Cable w spring Clevis Clevis Pin Cotter Pin Bushing for Brake Lever Woodruff Key Flat Washer 5 16 3 8 ID Flat Washer 3 16 1 4 ID Flat Washer 1 4 5 16 ID Parking Brake Latch Decal Handle grip 1 Dump Handle Grip 4 x 1 1 4 Left Corner Bracket Nylon Lock Nut 1 4 Nut 10 32 Handle Grip 1 x 1 4 x 4 Nylon Lock Nut 5 16 Nut for Tie Rod Ends 5 16 24 Nylon Lock Nut 3 8 Parking Brake Latch Plugs for 1 14 GA Square Tubing Right Corner Bracket Rod Ends 5 16 24 Male Roll Pin for Brake 3 16 x 1 3 4 Ref 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 58 59 60 61 62 63 64 65 66 67 68 69 70 71 Part 110961 114701 111481 111501 109121 134431 111581 111591 111421 111701 111641 111651 112581 108791 113071 123441 110951 110941 119831 110771 110131 110121 110331 110641 109221 110851 109871 109601 111191 108991 131091 110601 111951 110461 Description Roll Pin 3 16 x 1 Bolt 1 4 x 1 2 Bolt 1 4 x 1 3 4 Allen HD Bolt 1 4 28 x 3 4 Carriage Bolt 1 4 x 3 4 Bolt 5 16 x 1 1 2 Bolt 5 16 x 1 Bolt 5 16 x 2 1 2 Bolt 5 16 x 3 4 Screw for Spring Bracket 10 32 1 2 Screw 10 x 1 1 4 Self tap drill Plywood
28. setvsdsdesdedssvestedescesdssasesdevedss cesdeestesesaascetevesedesesies tudecsostessssessese 4 BEFORE STAR TING 4 Jo DU JU HILOS TAR TING cease 4 MANUAL REGOIE STARTING Pe NUES V HE Ee cede Erro VE de eee eve a o eve ee reda vene ev re 4 STOPPING THE ENGINE ce eet es oe ete ve ee Cb PI RU eer ES EXE dee vo RUE Fe ve En UE VU Te e UE V E UN NEUE 5 ENGAGING THE TERANSMISSION Ve De ey eb HER e xeu rre vU Dee e Ceca eve ex Pega ve ve NE Und 5 ENGAGING THE DRIVE erret ttt eer TERR VE Te cules RU FEET eu Pere RE Ted Soe ONT Ee eves e rna 5 OPERATING TIPS eL 6 UNEVEN FERRAIN 6 TSO ADDING 7 DUMPING ze Basa estore Rid E iie ier eren dabo o siet ems 7 iare d ere tutte e en reip eerte Masten e ee aeree e E ee ta et 8 USING THE OPTIONAT t eie eere a ne aI 9 MAINTENANCE Desc P c 10 CET 10 CHANGING THE OIL msa na eene PLEASE SEE ENGINE MANUFACTURER S OWNER S MANUAL CLEANING REPLACING THE CARTRIDGE AIR P
29. sssssssns BACK COVER iv DR POWERWAGON Safety amp Operating Instructions Assembly The DR POWERWAGON is shipped almost completely assembled Please read the following instructions before removing the machine from the crate and completing the assembly Parts Bag Contents 1 5 16 x 1 1 2 Bolt for the Handlebar 1 5 16 Lock Nut for the Handlebar 1 Cable Tie for the Cable Assembly Install the Upper Handlebars Tools Needed 2 1 2 or adjustable wrenches 1 Position the cable assembly on the right side of the frame when standing in the operating position Secure the cable assembly to the frame with the cable tie provided Figure 1 2 Position the upper handlebar inside the lower handlebar mount the 5 16 x 1 1 2 bolt and secure it with the 5 16 lock nut Figure 2 You may adjust the handlebar height at any time by removing the bolt and repositioning the upper handlebar in a different hole WARNING The DR POWERWAGON is shipped without gas and oil DO NOT attempt to start your DR POWERWAGON until assembly is complete and youve added the correct amounts of gas and oil 5998 Cable Assembly to Frame with Cable Tie Mount Upper n Handlebar and Secure Bolt Figure 2 DR POWERWAGON Safety amp Operating Instructions 1 Connect the Battery Wires Electric Starting Model Connect the red wire from the battery to the red wire on the wiring harness Figure 3 LF
30. ty amp Operating Instructions Replacing the Brake Pads If the DR POWERWAGON rolls on slopes when the brake is set and you have tried adjusting the brake page 14 the brake pads probably need to be replaced Tools needed 1 2 or adjustable wrench 2 3 8 box open end or socket wrenches Allen wrench set brake pads set of two part 110801 WARNING Always disconnect the spark plug wire before servicing your machine 1 Find a level area to work The parking brake should NOT be engaged Chock the wheels so the machine can not move 2 Locate the brake caliper at the right front Remove Two Bolts A of the machine Figures 27 amp 30 Remove the two mounting bolts on the caliper with a 3 8 wrench Figure 30 then carefully remove the caliper Figure 31 Note The caliper contains four small parts the brake pad the backing plate and two small actuator pins As you let the caliper hang from its attaching hardware keep track of these parts they could fall out Clean away any debris from the caliper and associated parts 3 Pull the brake disk off the spline shaft and remove the old brake pad from behind the disk Figure 31 Replace it with one of the new pads then reinstall the brake disk ke 4 Put the second new brake pad on the caliper then reinstall the assembly Make sure the brake arm is in the upright position and the recessed cut out on the caliper is facing up with the namepl
31. wing the bulb to return completely to its original position between pushes Note Do not use the primer when restarting a warm engine 2 Turn the key Figure 8 to the START position 4 DR POWERWAGON Safety amp Operating Instructions 3 Pull the recoil rope Figure 8 slowly until you feel drag Let the rope rewind slowly Then pull the recoil with a rapid full arm stroke to start the engine Let the recoil rope slowly return to the starter One pull usually starts the DR POWERWAGON but repeat if necessary Note Holding the throttle control lever at half throttle may help with starting Stopping the Engine 1 Shift the transmission to N neutral 2 Set the brake and turn the key to the OFF position The DR POWERWAGON switch has a pressure lock insert which prevents the key from vibrating loose during use To remove the key turn the key to the left OFF position push in on it and then quickly and firmly pull it out If the key is difficult to remove try spraying FLUID or a similar lubricant into the switch Engaging the Transmission Forward Gears To shift the transmission from neutral into the 5 forward gears first release the throttle lever then move the shift lever forward and position it next to the desired drive range Figure 9 Use first gear for slower speeds heavy loads or more power Use second gear for transport Reverse To shift the transmission into reverse first rel
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