DR® POWERWAGON
Safety & Operating Instructions
Model: SUBURBAN
™
™
These Safety & 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
thoroughly familiar with them.
®
POWERWAGON™ should read these instructions and be
And congratulations on your purchase of a new
®
DR
POWERWAGON™!
We have done our utmost to ensure that your DR
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 DR® POWERWAGON™. We don't want
you to get injured, so please take a few moments to read the following guidelines for safely
operating your new machine.
Dress Appropriately
• Wear shoes with non-slip treads when using your DR
shoes, we recommend that you wear them. Do not use the machine while barefoot or wearing
open sandals.
®
POWERWAGON™. If you have safety
• 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 & 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 the DR
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
depending on the speeds used, loads carried and terrain covered.
™
will run continuously for about 45 minutes. This running time will vary
®
POWERWAGON™. Remove any
®
Operating the Machine Safely
Unless there is very good artificial light, only use the DR® POWERWAGON™ during the daylight
hours.
®
Always operate the DR
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 DR® 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 & Operating Instructions i
POWERWAGON™ from behind the handlebars, never from the side.
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 slowest 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 All 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 your local fire marshal or forest service for specific information in your area.
DR® POWERWAGON™ Safety & Operating Instructions ii
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:
1. 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.
2. IF WITHIN THE FIRST 30 DAYS of actual hands-on use you have questions or you are less
than 100% satisfied with your 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
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.)
3. We operate, for our Owners, a 7-Day-a-Week Customer 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: _____/_____/_____
®
POWERWAGON™, please write or call us at 1(800)DR-
®
POWERWAGON™ for a full refund of its
DR® POWERWAGON™ Safety & Operating Instructions iii
Table of Contents
SAFETY INFORMATION ................................................................................................................................................I
D
RESS APPROPRIATELY .................................................................................................................................................... I
P
REPARATION ................................................................................................................................................................... I
PERATING THE MACHINE SAFELY................................................................................................................................... I
O
W
ARNING TO ALL CALIFORNIA AND OTHER USERS......................................................................................................... II
ASSEMBLY........................................................................................................................................................................ 1
I
NSTALL THE UPPER HANDLEBARS .................................................................................................................................. 1
C
ONNECT THE BATTERY WIRES....................................................................................................................................... 2
F
ILL THE MACHINE WITH OIL AND GAS ........................................................................................................................... 2
C
HECK THE TIRE PRESSURE ............................................................................................................................................. 2
CONTROLS & FEATURES............................................................................................................................................. 3
STARTING & OPERATING ........................................................................................................................................... 4
B
EFORE STARTING ........................................................................................................................................................... 4
E
LECTRIC-STARTING........................................................................................................................................................ 4
M
ANUAL RECOIL-STARTING............................................................................................................................................ 4
S
TOPPING THE ENGINE..................................................................................................................................................... 5
E
NGAGING THE TRANSMISSION........................................................................................................................................ 5
E
NGAGING THE DRIVE ..................................................................................................................................................... 5
OPERATING TIPS............................................................................................................................................................ 6
U
NEVEN TERRAIN & SLOPES ........................................................................................................................................... 6
L
OADING.......................................................................................................................................................................... 7
D
UMPING ......................................................................................................................................................................... 7
HANGING BODIES .......................................................................................................................................................... 8
C
U
SING THE OPTIONAL STAKE BODY ................................................................................................................................9
MAINTENANCE............................................................................................................................................................. 10
B
ATTERY ....................................................................................................................................................................... 10
HANGING THE OIL...................................................................... PLEASE SEE ENGINE MANUFACTURER'S OWNER'S MANUAL
C
C
LEANING/REPLACING THE CARTRIDGE AIR CLEANER ............... PLEASE SEE ENGINE MANUFACTURER'S OWNER'S MANUAL
C
LEANING THE STATIC GUARD & COOLING SYSTEM................... PLEASE SEE ENGINE MANUFACTURER'S OWNER'S MANUAL
C
LEANING/REPLACING THE SPARK PLUG .................................... PLEASE SEE ENGINE MANUFACTURER'S OWNER'S MANUAL
L
UBRICATION................................................................................................................................................................. 12
A
DJUSTING THE BRAKE.................................................................................................................................................. 14
R
EPLACING THE BRAKE PADS ........................................................................................................................................ 15
EMOVING THE FRONT WHEELS .................................................................................................................................... 16
R
A
DJUSTING THE SHIFT LEVER ........................................................................................................................................ 16
END OF SEASON & STORAGE................................................................................................................................... 17
TROUBLESHOOTING .................................................................................................................................................. 18
PARTS LIST .................................................................................................................................................................... 20
MAIN FRAME ASSEMBLY .......................................................................................................................................... 22
HANDLEBAR/CONTROLS ASSEMBLY.................................................................................................................... 23
AXLE ASSEMBLY.......................................................................................................................................................... 24
MOLDED BODY ASSEMBLY ...................................................................................................................................... 25
STAKE BODY ASSEMBLY........................................................................................................................................... 26
DAILY CHECK LIST FOR THE DR
®
POWERWAGON™.................................................................BACK COVER
DR® POWERWAGON™ Safety & Operating Instructions iv
Assembly
The DR® POWERWAGON™ is shipped almost completely assembled. Please read the
following instructions before
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.
removing the machine from the crate and completing the
WARNING!
The DR® POWERWAGON™ is shipped
without gas and oil. DO NOT attempt to
start your DR
assembly is complete, and you've added
the correct amounts of gas and oil.
®
POWERWAGON™ until
Figure 1
DR® POWERWAGON™ Safety & Operating Instructions 1
Figure 2
Connect the Battery Wires
Electric-Starting Model: Connect the red wire
from the battery to the red wire on the wiring
harness (Figure 3).
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
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 lbs. psi
All-Terrain Tires 14-20 lbs. psi
Caster Wheel 50 lbs. psi
Please Note: The heavier the load the higher
the tire pressure should be. However, do not
exceed the maximum recommended load or
pressure.
DR® POWERWAGON™ Safety & Operating Instructions 2
Figure 5
Controls & Features
DR® POWERWAGON™ Safety & Operating Instructions 3
Figure 6
Starting & Operating
Before Starting
Check the oil and 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.
Figure 7
Note: Holding the throttle control lever at
half throttle may help with starting.
If the engine won't start with the key the
battery may need to be charged. Please see
page 10 for information on battery care and
maintenance.
Your engine is also equipped with a manual
recoil starter. Please see the instructions
below.
Manual Recoil-Starting
Can be used for both Electric- and ManualStarting models.
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.
Figure 8
Note: Do not use the primer when restarting a warm engine.
2. Turn the key (Figure 8) to the "START" position.
DR® POWERWAGON™ Safety & Operating Instructions 4
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
Note: Holding the throttle control lever at half throttle may help with starting.
POWERWAGON™, but repeat if necessary.
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™ key 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 FILM
™
or a similar lubricant into the switch.
Engaging the Transmission
Forward Gears
To shift the transmission from neutral into the
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
release the throttle lever then move the shift
lever to the right and all the way backwards.
Engaging the Drive
With the engine running, slowly squeeze the
throttle lever on the right handlebar until you
reach desired speed.
Note: Squeezing the throttle lever quickly will
make the DR
forward. Squeeze the throttle lever slowly
and ease
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.
®
POWERWAGON™ jump
the machine into gear.
Figure 9
Figure 10
DR® POWERWAGON™ Safety & Operating Instructions 5
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