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DR ® POWER W AGON ™ Safety & Operating Instructions Model: SUBURBAN ™ These Safety & Operating Instructions as well as the engine manufacturer's owner's manual contain important inform ation concerning safety, operating procedures, maintenance, troubleshootin g and assembly tips. Everyone who operates the DR ® POWERWAGON ™[...]

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. W e wa nt to answer or correct them as quickly as possible. ([...]

DR ® POWERWAGON ™ Safety & Operating Instructions i 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 moment s to read the following guidelines for safely operating your new machine. Dress Appropriately • Wear shoes with non-slip trea[...]

DR ® POWERWAGON ™ Safety & Operating Instructions ii 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 lo ad, the more chance the m achine may tip. Also, loads may shift during[...]

DR ® POWERWAGON ™ Safety & Operating Instructions iii W e W ant Y ou to be T ot ally Satisfied The DR ® POWERWAGON ™ is designed to provide year after y ear of trouble-free performance. To ensure that you are totally satisf ied with this importan t purchase, we offer the following three -part Assurance of Satisfaction: 1. DR ® POWERWAGON[...]

DR ® POWERWAGON ™ Safety & Operating Instructions iv T able of Content s SAFETY INFORMATI ON ............................................................................................................. ................................... I D RESS A PPROPRIATELY ................................................................................[...]

DR ® POWERWAGON ™ Safety & Operating Instructions 1 Assembly The DR ® POWERWAGON ™ is shipped almost completely assembled. Please read the following instructions before removing the ma chine 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 [...]

DR ® POWERWAGON ™ Safety & Operating Instructions 2 Connect the Battery Wires Electri c-Start ing Model : Connect the red wire from the battery to the red wire on the wiring harness (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[...]

DR ® POWERWAGON ™ Safety & Operating Instructions 3 Controls & Features Figure 6[...]

DR ® POWERWAGON ™ Safety & Operating Instructions 4 S t arting & 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 neutra l. Electric-Starting 1. When starting a cold engine, push the primer[...]

DR ® POWERWAGON ™ Safety & Operating Instructions 5 3. Pull the recoil rope (Figure 8) slowly, until you feel drag. Let th e rope rewind slowly. Then pull the recoil with a rapid full arm stroke to start the engine. Let the recoil rope slowly re turn to the starter. One pull usually star ts the DR ® POWERWAGON ™ , but repeat if necessary.[...]

DR ® POWERWAGON ™ Safety & Operating Instructions 6 Operating T ip s 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, bu t always use the parkin g brake[...]

DR ® POWERWAGON ™ Safety & Operating Instructions 7 Loading ! WARNING: The recommended load limit for the DR ® POWERWAGON ™ is 400 lbs 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 gui delines when loading your DR ® POWERW[...]

DR ® POWERWAGON ™ Safety & Operating Instructions 8 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 loa d. In this case, you'll need to manually unload part of what you are hauling from the back of the bed, until the lo ad[...]

DR ® POWERWAGON ™ Safety & Operating Instructions 9 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 overs[...]

DR ® POWERWAGON ™ Safety & Operating Instructions 10 Maintenance For Engine Maintenance, Please Refer to the Engine Manufacturer's Owner's Manual. Regular maintenance is the way to ensure the be st performance from your m achine. Follow the instructions below, and those in the engine manufacturer's owner's m anual to keep[...]

DR ® POWERWAGON ™ Safety & Operating Instructions 11 Charging the Battery If the battery loses its charge, you'll n eed to use a trickle charger (like the DR ® Battery Charger ) to recharge it. The charger s hould have an output of 12 volts at no more than 2 amps. • At 1 amp the battery may need to be charged for as m uch as 48 hours[...]

DR ® POWERWAGON ™ Safety & Operating Instructions 12 Lubrication Tools & Supplies Needed : • flexible hose grease gun • lithium grease • 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 occas io[...]

DR ® POWERWAGON ™ Safety & Operating Instructions 13 3. Lubricate the upper brake cable with FLUID FILM ™ or similar lubricant (Figure 24) . 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. 5. Lubricate th[...]

DR ® POWERWAGON ™ Safety & Operating Instructions 14 Adjusting the Brake If the DR ® POWERWAGON ™ rolls on slopes when the park ing brake is set, or you can't get the parking brake to set, the brake needs to be adjusted. Tool Needed : • 1/2" wrench ! WARNING: Always disconnect the spark plug wire before servicing your machine.[...]

DR ® POWERWAGON ™ Safety & Operating Instructions 15 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 ?[...]

DR ® POWERWAGON ™ Safety & Operating Instructions 16 Removing the Front Wheels Tools & Supplies Needed : • (2) 7/16" wrenches • block to raise machine off ground ! 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&qu[...]

DR ® POWERWAGON ™ Safety & Operating Instructions 17 End of Season & S torage ! WARNING: Always disconnect the spark plug wire before servicing your machine. Please refer to your engine manufacturer's ow ner's m anual for engine-specific procedures. If your DR ® POWERWAGON ™ will be idle for more than 30 days, we recomm end [...]

DR ® POWERWAGON ™ Safety & Operating Instructions 18 T roubleshooting ! 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 Ö Check for adequate fresh fuel. Also chec[...]

DR ® POWERWAGON ™ Safety & Operating Instructions 19 Alternator isn't recharging the battery Ö Have alternator checked by an authorized engi ne service center. The alternator should be checked with a fully charge d battery and should put out 12 to 13.5 volts (1.5 to 2 amps). Shifting Won't shift into reverse or high gears Ö Shift[...]

DR ® POWERWAGON ™ Safety & Operating Instructions 20 Part s List Please refer to the numbered dra wings on pages 22-26. Note: Not all parts numbers listed app ear on the drawings. Ref# Part # Description 1 108921 Ball Bearing, 2-Hole Flanges 2 108931 Ball Bearing, 3/4" Bore 3 131191 Battery (Electric-Starting) 4 135101 Battery Clamp (El[...]

DR ® POWERWAGON ™ Safety & Operating Instructions 21 Ref# Part # Description 72 112061 Key Switch w/ Hardware & Key for Recoil-Start 73 112051 Key Switch w/ Hardware & Key for Electric-Start 75 109461 Throttle Cable 76 111611 Screw 3/8" x 2-3/4" 77 111341 Screw 7/16" Fine x 3/4" 78 110201 Gear Box (Transmission) 7[...]

DR ® POWERWAGON ™ Safety & Operating Instructions 22 Main Frame Assembly Figure 35[...]

DR ® POWERWAGON ™ Safety & Operating Instructions 23 Handlebar/Controls Assembly Figure 35[...]

DR ® POWERWAGON ™ Safety & Operating Instructions 24 Axle Assembly Figure 36[...]

DR ® POWERWAGON ™ Safety & Operating Instructions 25 Molded Body Assembly Figure 37[...]

DR ® POWERWAGON ™ Safety & Operating Instructions 26 S t ake Body Assembly Figure 38[...]

DR ® POWERWAGON ™ Safety & Operating Instructions 27 Notes[...]

DR ® POWERWAGON ™ Safety & Operating Instructions 28 Notes[...]

DR ® POWERWAGON ™ Safety & Operating Instructions 29[...]

DR ® POWERWAGON ™ Safety & Operating Instructions 30 Daily Check List for the DR ® POWER W AGON ™ ! WARNING: Always disconnect the spark plug wir e before servicing your machine. 9 OIL: With the DR ® POWERWAGON ™ on a level surface, lift the dump body, remove the oil fill cap and check the oil level. Fill the reservoir with SAE30 de te[...]