DR® POWER GRADER™ SAFETY & OPERATING INSTRUCTIONS READ AND UNDERSTAND THIS MANUAL AND ALL INSTRUCTIONS BEFORE OPERATING THIS GRADER.
Congratulations on your purchase of a new DR POWER GRADER! We have done our utmost to ensure that your DR POWER GRADER 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.
Table of Contents CHAPTER 1............................................................................................................................. 1 INTRODUCING THE DR POWER GRADER .................................................................. 1 Conventions used in this manual ................................................................................... 1 CHAPTER 2.............................................................................................................................
CHAPTER 7........................................................................................................................... 32 PARTS LIST, SCHEMATIC DIAGRAM AND WARRANTY ............................................ 32 Parts List - DR POWER GRADER Assembly ................................................................. 32 Schematic - DR POWER GRADER Assembly................................................................ 33 Parts List - DR POWER GRADER Control Assembly ............................
CHAPTER 1 INTRODUCING THE DR POWER GRADER This manual will help you set up and safely operate your new DR POWER GRADER. 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.
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CHAPTER 2 GENERAL SAFETY RULES READ THIS SAFETY & OPERATING INSTRUCTIONS MANUAL BEFORE YOU USE THE DR POWER GRADER. BECOME FAMILIAR WITH THE SERVICE RECOMMENDATIONS TO ENSURE THE BEST PERFORMANCE FROM YOUR POWER GRADER. Labels Your DR POWER GRADER carries prominent labels as reminders for its proper and safe use. Shown below are copies of all the labels that appear on the equipment.
Protecting Yourself and Those Around You ALWAYS TAKE THE FOLLOWING PRECAUTIONS WHEN OPERATING THIS GRADER: • ALWAYS WEAR PROTECTIVE GOGGLES OR SAFETY GLASSES WITH SIDE SHIELDS WHILE GRADING TO PROTECT YOUR EYES FROM POSSIBLE THROWN BITS OF DIRT OR GRAVEL. • WEAR SHOES WITH NON-SLIP TREADS WHEN USING YOUR DR POWER GRADER. IF YOU HAVE SAFETY SHOES, WE RECOMMEND WEARING THEM. DO NOT USE THE GRADER WHILE BAREFOOT OR WEARING OPEN SANDALS. • WEAR A HELMET WHEN OPERATING AN ATV.
Safety for Children TRAGIC ACCIDENTS CAN OCCUR IF THE OPERATOR IS NOT ALERT TO THE PRESENCE OF CHILDREN. CHILDREN ARE OFTEN ATTRACTED TO THE GRADING ACTIVITY. NEVER ASSUME THAT CHILDREN WILL REMAIN WHERE YOU LAST SAW THEM. • • • • KEEP CHILDREN OUT OF THE GRADING AREA AND UNDER THE WATCHFUL CARE OF A RESPONSIBLE ADULT. BE ALERT, STOP AND TURN THE TOW VEHICLE OFF IF CHILDREN ENTER THE WORK AREA. NEVER ALLOW CHILDREN TO OPERATE THE DR POWER GRADER.
Handling the Battery Safely • • USE ONLY THE 12-VOLT, LEAD-ACID, RECHARGEABLE BATTERY, AND THE 12-VOLT BATTERY CHARGER THAT SHIPPED WITH YOUR GRADER, OR THEIR COUNTRY HOME PRODUCTS REPLACEMENT. USING THE WRONG TYPE OF BATTERY OR CHARGER COULD CAUSE A FIRE OR EXPLOSION RESULTING IN SERIOUS INJURY. NEVER LIFT OR CARRY THE BATTERY BY THE WIRES OR CONNECTORS. THIS CAN DAMAGE THE BATTERY AND POSSIBLY CAUSE A FIRE RESULTING IN SERIOUS INJURY. LIFT AND CARRY THE BATTERY BY THE CASE ONLY.
THE DR POWER GRADER MUST BE 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 POWER GRADER: • • • • • • • • • • • KEEP IN MIND THAT THE OPERATOR OR USER IS RESPONSIBLE FOR ACCIDENTS OR HAZARDS OCCURRING TO OTHER PEOPLE, THEIR PROPERTY, AND THEMSELVES. DO NOT USE THE DR POWER GRADER TO DRAG, TOW, OR CARRY ITEMS.
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CHAPTER 3 SETTING UP YOUR DR POWER GRADER 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 new DR POWER GRADER by reviewing Figure 1 before beginning the steps outlined in this chapter. If you have any questions at all, please feel free to contact our Customer Service Representatives at our Toll-Free number: 1-800-DR-OWNER (376-9637).
Unpacking the DR POWER GRADER NOTE: Unpacking the DR POWER GRADER is a two-person job. We recommend you have an extra set of hands available before you begin, as the DR POWER GRADER weighs about 230 lbs. Tools Required: • Metal Shears (Side Cutters) • Knife • Eye Protection • 9/16" Wrench WEAR EYE PROTECTION WHEN CUTTING THE BANDING. THE BANDING MAY HAVE A LOT OF TENSION ON IT AND MAY SNAP AND CUT YOU. ALWAYS STAND TO ONE SIDE WHEN CUTTING THE BAND. 1.
Parts Checklist Country Home Products ships the following items with your new DR POWER GRADER. Please check to make sure you have everything listed below. If you are missing any of these items, please call Customer Service Toll-Free 1-800-DR-OWNER (376-9637) for assistance.
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Assembling the DR POWER GRADER Tools Needed: • (2) 9/16" Wrench or Socket Installing the Battery 1. Locate the Clevis Base w/Battery Assembly 2. Using two (2) 9/16" Wrenches, bolt the Clevis Base w/Battery Assembly to the left Side Rail with the three (3) 3/8"-16 x 1-1/2" Bolts, 3/8" Flat Washers and 3/8" Nylon Lock Nuts (Figure 3). (-) Terminal (+) Terminal Clevis Base w/Battery Assembly Battery Note: Actuator shown installed, you will install this later.
Attaching the Yoke Tool Needed: • (2) 9/16" Wrench 1. Position the Yoke in front of the DR POWER GRADER with the Receptacle Box facing up (Figure 4). 2. Attach each side of the Yoke in the upper hole on the outside of the Side Rail using a 3/8"-16 x 11/2" Bolt, 3/8" Flat Washer and 3/8" Lock Nut (Figure 5). Do not tighten at this time 3.
Installing the Linear Actuator 1. Remove the Hitch Clip, Clevis Pin, and two (2) Spacers assembled on the Clevis Base w/Battery Assembly (Figure 8). Clevis Base w/Battery Assembly Linear Actuator 2. Locate the Linear Actuator and place it between the Clevis Base w/Battery Assembly and the Axle Clevis with the Actuator Arm facing the forward and Motor facing down (Figure 9). Spacers 3. Reinsert the Spacers, Clevis Pin, and Hitch Pin in the Clevis Base w/Battery Assembly (Figure 8).
10. Reconnect the Control Cable to the Receptacle Box in the Yoke and raise the DR POWER GRADER (lower the wheels) with the Control Box Rocker Switch in the Raise position. 11. With the help of another person, you can now roll the DR POWER GRADER off the shipping pallet. NOTE: You must now fully charge the Battery of your new DR POWER GRADER before using the machine. See the next page. Linear Actuator Arm Insert Spacer from the top down.
Charging the Battery ELECTRICAL HAZARD: PREVENT FIRE • • • • • • NEVER MODIFY YOUR GRADER’S ELECTRICAL SYSTEM. MODIFICATIONS COULD RUIN THE ELECTRICAL SYSTEM AS WELL AS CAUSE A FIRE, RESULTING IN SERIOUS INJURY. USING ELECTRICAL COMPONENTS OTHER THAN THOSE SUPPLIED WITH YOUR GRADER COULD CAUSE THE ELECTRICAL SYSTEM TO OVERHEAT, EXPLODE, OR START A FIRE. ONLY ADULTS SHOULD HANDLE THE BATTERY, IT CONTAINS SULFURIC ACID (AN ELECTROLYTE). THE BATTERY IS HEAVY; DROPPING IT COULD RESULT IN SERIOUS INJURY.
Charging the Battery is a simple process. Leave the Battery in your DR POWER GRADER when you charge it. 1. Attach the Black (-) alligator clipped wire from the Charger Adapter to the (-) terminal of the Battery, then attach the Red (+) alligator clipped wire to the (+) Battery terminal. 2. Plug the Charger into a standard wall outlet. • Every time you finish using your DR POWER GRADER, recharge the Battery. The time it takes to recharge the Battery depends on how drained it is when you start.
Install the Scarifying Teeth Plates The three (3) Scarifying Teeth Plates (there are four (4) plates on the 60" Model) are installed upside down for shipping. The following procedure is for installing the Scarifying Teeth Plates. Tool Needed: • (2) 9/16" Wrench 1. Use the Linear Actuator to raise the front of the DR POWER GRADER to the highest position. PRIOR TO PERFORMING THE NEXT STEPS, DISCONNECT THE CONTROL BOX OR BATTERY TO PREVENT ACCIDENTAL ACTIVATION OF THE SCARIFYING TEETH PLATES. 2.
Adjustable Tow Bar Yoke Connecting the DR POWER GRADER to your Tow Vehicle Selected Hitch Configuration Shear-Bolt The following procedure is for connecting the DR POWER GRADER to your tow vehicle using the Adjustable Tow Bar with the Hitch Pin configuration (Lawn Tractor) or Ball Hitch configuration (ATV). Tools Needed: • (2) 1/2" Wrench • (2) 9/16" Wrench Figure 13 1.
Attaching the DR POWER GRADER Control Box w/Rocker Switch The following procedure includes the steps necessary for attaching the DR POWER GRADER Control Box w/Rocker Switch to your Tow Vehicle. There are two (2) options for attaching the Control Box: 1. Hang the Control Box by the attached U-Bolt (Figure 16) in an accessible and comfortable position on your Tow Vehicle from which you can operate the Height Adjustment Control Box w/Rocker Switch, or 2.
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CHAPTER 4 OPERATING YOUR DR POWER GRADER This chapter covers the procedures for operating your new DR POWER GRADER and discusses basic operation features. You may find it helpful to review the Controls and Features on page 9. Operating Safety • • • • NEVER ALLOW ANYONE TO OPERATE THE DR POWER GRADER WITHOUT FIRST READING AND UNDERSTANDING ALL INSTRUCTIONS IN THIS MANUAL. BE THOROUGHLY FAMILIAR WITH THE CONTROLS AND THE PROPER USE OF YOUR GRADER BEFORE USING. NEVER LET PEOPLE RIDE ON THE GRADER.
Operating Parameters There are four (4) different types of tow vehicles recommended for the DR POWER GRADER. Each vehicle type has specific strengths, weaknesses, and operating parameters when used with the DR POWER GRADER. • - 14 HP and/or 500 pound tractor minimum for the 48" Model. - 19 HP and/or 500 pound tractor minimum for the 60" Model. - 5° slope or less. - Material loosened during grading increases traction difficulties. - Very good speed control and turning radius.
Operating Tips • • • CLEAN OUT THE BOTTOM OF THE BATTERY HOLDER COMPLETELY BEFORE RE-INSTALLING THE BATTERY. USING THE 8" HOOK AND LOOP STRAP, HANG THE EXTRA CABLE TO KEEP IT OUT OF THE WHEELS. LOWER THE GRADER FRAME COMPLETELY TO THE GROUND SURFACE WHEN TRANSPORTING ON A TRAILER, PARKING ON A HILL, OR SERVICING THE GRADER. • Use additional weight (up to 70 pounds) in the Weight Tray when grading hard pack to begin scarification.
FAQ’s • Can the DR POWER GRADER create a crown in the road? Answer: No • Can the DR POWER GRADER maintain the crown in the road? Answer: Yes, you can grade each side separately. • Can the DR POWER GRADER ruin the crown in the road? Answer: Yes, only if you grade down the centerline of the road. • How long will the battery last? Answer: Approximately 20 hours or 800 up/down cycles.
CHAPTER 5 MAINTAINING THE DR POWER GRADER This chapter covers regular maintenance procedures that will ensure the best performance and long life of your DR POWER GRADER. WHEN PERFORMING ANY MAINTENANCE, YOU MUST FIRST SHUT OFF THE TOW VEHICLE, SET THE PARKING BRAKE AND UNPLUG THE CONTROL CABLE. READ THE "GENERAL SAFETY RULES" (CHAPTER 2) OF THIS MANUAL BEFORE PERFORMING ANY REPAIRS OR MAINTENANCE. Regular Maintenance Check: • Keep the battery charged. See page 17.
Caring for the Battery Proper care can lengthen the life of a battery. Follow these recommendations to ensure your battery’s best performance and long life: • Do not continue to operate your DR POWER GRADER with a low battery. • Try to keep your battery at full charge to maximize its life. If the machine is not used, charge the battery monthly. See “Charging the Battery” on page 17. • Before charging the battery, observe its external appearance and keep it clean and dry.
Replacing the Scarifying Teeth Plates The following procedure is for replacing the three (3) Scarifying Teeth Plates (there are four (4) plates on the 60" Model). To replace the Scarifying Teeth Plates: Tool Needed: • (2) 9/16" Wrench 1. Use the Linear Actuator to raise the front of the DR POWER GRADER to the maximum position. PRIOR TO PERFORMING THE NEXT STEPS, DISCONNECT THE CONTROL BOX OR BATTERY TO PREVENT ACCIDENTAL ACTIVATION OF THE SCARIFYING TEETH PLATES. 2.
Lubrication WHEN PERFORMING ANY MAINTENANCE, YOU MUST FIRST SHUT OFF THE TOW VEHICLE, SET THE PARKING BRAKE AND UNPLUG THE CONTROL CABLE. Tools and Supplies Needed • Flexible hose grease gun • Lithium grease NOTE: Pump the grease gun only until you feel slight resistance (2 - 3 pumps). 1. Lubricate the Rear Fixed Wheel, the Front Caster Wheel and Caster bearings at the grease fittings every 25 hours of operation (Figure 21).
CHAPTER 6 TROUBLESHOOTING Most problems are easy to fix. Consult the Troubleshooting Table below for common problems and their solutions. If you continue to have trouble, call Country Home Products, Inc. for support. Troubleshooting Table WHEN PERFORMING ANY MAINTENANCE, YOU MUST FIRST SHUT OFF THE TOW VEHICLE, SET THE PARKING BRAKE, LOWER THE GRADER TO THE GROUND, AND UNPLUG THE CONTROL CABLE. SYMPTOM Frequently have to re-align the Scarifying Teeth Plates.
CHAPTER 7 PARTS LIST, SCHEMATIC DIAGRAM AND WARRANTY Parts List - DR POWER GRADER Assembly NOTE: Part numbers listed are available through Country Home Products, Inc. Ref# Part# Description Ref# Part# Description 01 Frame, 48" Subassembly Frame, 60" Subassembly Rail, Side Scarifying Teeth Plate (48" or 60" model) Bracket, Caster Axle Assembly (48" model) Axle Assembly (60" model) Blade, Scraper (48" model) Blade, Scraper (60" model) Bracket, Battery Mount Spacer, .688" ID, 1.0" OD, 1.
Schematic - DR POWER GRADER Assembly 070115 CALL TOLL-FREE 1-800-DR-OWNER 33
Parts List - DR POWER GRADER Control Assembly NOTE: Part numbers listed are available through Country Home Products, Inc. Ref# Part# Description 01 191491 221881 211521 191771 193731 191861 211551 191691 119851 111491 191871 112391 112381 112411 101811 110751 110731 110761 211561 111591 214011 191631 191641 193421 191731 191651 112141 Yoke (48" model) Yoke (60" model) Bar, Tow Hitch, Tow, Tractor Hitch, Tow Hook Bracket, Receptacle Pin, Snap, Safety, 3/8" x 2.
Schematic - DR POWER GRADER Control Assembly 060718 CALL TOLL-FREE 1-800-DR-OWNER 35
Wiring Diagram 061203 36 DR® POWER GRADER™
DR® POWER GRADER 2-Year Limited Warranty Terms and Conditions The DR® POWER GRADER™ is warranted for two (2) years against defects in materials or workmanship when put to ordinary and normal consumer use; ninety (90) days for any other use. For the purposes of all the above warranties, “ordinary and normal consumer use” refers to non-commercial residential use and does not include misuse, accidents, or damage due to inadequate maintenance. Country Home Products, Inc.
Daily Checklist for the DR POWER GRADER To help maintain your DR POWER GRADER for optimum performance, we recommend you follow this checklist each time you use your machine. [ ] HARDWARE: Check all nuts and bolts to be sure that the components are secure. [ ] FRAME: Check all welds to be sure that the frame is in tact and secure. [ ] CLEAN: Make sure that mating surface between the Scarifying Teeth Plates and the Frame is clean and free of debris. [ ] BATTERY: Make sure the Battery is fully charged.
