DR 5.00 HP Power Wagon User Manual
DR® POWERWAGON™ 5.0
Safety & Operating Instructions
Please read instructions before operating the DR POWERWAGON 5.0
And congratulations on your purchase of a new DR POWERWAGON 5.0!
We have done our utmost to ensure that your DR POWERWAGON 5.0 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 5.0! 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, Inc.
SALES MANAGER
COPYRIGHT
©2005 Country Home Products, Inc. All rights reserved.
DOCUMENTATION
Written by: Ed Melen of EVM Technical Writing
Country Home Products, Inc.
Meigs Road
P.O. Box 25
Vergennes, VT 05491
Toll-free phone: 1-800-DR-OWNER (376-9637)
Fax: 1-802-877-1213
Web site: www.dr-owner.com
E-mail: info@chp.com
ii DR POWERWAGON 5.0 Safety & Operating Instructions
Table of Contents
Chapter 1: Introducing the DR POWERWAGON 5.0.............................................1
Conventions used in this manual.................................................................................................... 1
Chapter 2: Safety Considerations..........................................................................2
Preparing to Use the DR POWERWAGON 5.0.............................................................................. 2
Safety Information Labels............................................................................................................... 2
Protecting Yourself......................................................................................................................... 4
Operating the Machine Safely........................................................................................................ 4
Safety with Gasoline-Powered Machines....................................................................................... 5
A Note to All Users......................................................................................................................... 6
Additional Information and Potential Changes................................................................................ 6
Chapter 3: Setting Up Your DR POWERWAGON 5.0............................................7
DR POWERWAGON 5.0 Controls and Features ........................................................................... 7
Unpacking the DR POWERWAGON 5.0........................................................................................ 8
Check the Tire Pressure................................................................................................................. 8
Adding Oil and Gasoline................................................................................................................. 9
Connect the Battery Wires.............................................................................................................10
Chapter 4: Operating Your DR POWERWAGON 5.0...........................................11
Before Starting the Engine ............................................................................................................11
Electric Starting.............................................................................................................................11
Manual Recoil Starting ..................................................................................................................12
Operating.......................................................................................................................................12
Stopping........................................................................................................................................13
Operating Tips...............................................................................................................................13
Loading..........................................................................................................................................13
Slopes & Uneven Terrain ..............................................................................................................14
Dumping........................................................................................................................................15
Chapter 5: Maintaining the DR POWERWAGON 5.0 ..........................................16
Regular Maintenance Checklist.....................................................................................................16
Battery Care..................................................................................................................................17
Charging the Battery .....................................................................................................................17
Lubrication.....................................................................................................................................18
Changing the Engine Oil................................................................................................................19
Removing and Replacing the Belt .................................................................................................20
Removing and Replacing the Front Wheels..................................................................................22
Adjusting the Parking Brake..........................................................................................................23
Parking Brake Cable Adjustment...................................................................................................24
Changing the Parking brake Pads.................................................................................................24
Replacing the Throttle Cable.........................................................................................................26
Adjusting the Shift Lever................................................................................................................28
Adjusting the Wheel Clutch ...........................................................................................................29
End of Season & Storage..............................................................................................................30
Chapter 6: Troubleshooting and Warranty .........................................................31
Troubleshooting Table...................................................................................................................31
DR POWERWAGON 5.0 Safety & Operating Instructions iii
Chapter 1: Introducing the DR POWERWAGON 5.0
This manual will help you set up and safely operate your new DR POWERWAGON 5.0.
Careful adherence to the safety and operating instructions in this manual will ensure many
years of productive use.
Please let us know if you have any questions or problems by contacting us via e-mail or our
toll-free phone number. Our contact information is listed inside the front cover of this
manual. When you call or write, please have your serial number or order number available so
we can help you quickly.
Conv entions used in this manual
WARNING! The exclamation point within a triangle alerts you to
essential operating, safety, and maintenance (servicing) instructions.
Important! This information is important in the proper use of your
machine. Failure to follow this instruction could result in injury to you or
damage to your DR POWERWAGON 5.0.
Tip: This is a helpful hint to guide you in getting the most out of your DR
POWERWAGON 5.0.
Tools Needed: This indicates you will need a special tool to perform a maintenance
function on your DR POWERWAGON 5.0.
Note: This information may be helpful to you.
If you are ever unsure about an action you are about to take, contact Country Home
Products’ toll-free support at 1-800-DR-OWNER (376-9637).
1 DR POWERWAGON 5.0 Safety & Operating Instructions
Chapter 2: Safety Considerations
g
Taking the time to read and observe all safety instructions will ensure many years of
productive use from your DR POWERWAGON 5.0 and help you avoid injury. Please take
a few moments to read the following guidelines for safely operating your new machine.
Preparing to Use the DR POWERWAGON 5.0
Read these
Safety & Operating Instructions
and the engine owner’s manual before
you use the DR POWERWAGON 5.0. Become familiar with the controls, engine and
service recommendations to ensure the best performance from your DR
POWERWAGON 5.0.
Check out the area you will be operating in BEFORE using your DR
POWERWAGON 5.0. Know what kind of terrain you will be moving over, and avoid
areas with poor footing.
Safety Information Labels
Take some time to become familiar with the following standard safety cautions applicable
to your DR POWERWAGON 5.0. Replace damaged or missing safety labels immediately.
#137581
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.
WARNING: Add Oil
Before S t artin
#127811
Engine
#153421
DR POWERWAGON 5.0 Safety & Operating Instructions 2
#153441
#153431
#180531
3 DR POWERWAGON 5.0 Safety & Operating Instructions
Protecting Y ourself
Wear shoes with non-slip treads when using your DR POWERWAGON 5.0. 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 might be caught on the machine’s
moving parts.
Operating the Machine Safe ly
WARNING! The items listed in this section will help you keep your DR
POWERWAGON 5.0 running smoothly and, most importantly, prevent injury to
yourself or others. Please review them carefully before starting your machine.
Built-in safety features, such as the Operator Presence System, are effective only when
maintained and kept in place.
Do not, under any conditions, remove, bend, cut, fit, weld, or otherwise alter standard
parts on the DR POWERWAGON 5.0. Modifications to your machine could cause
personal injuries and will void your warranty.
Use only approved DR parts.
Do not use the DR in a manner not in accordance with these instructions.
Be particularly careful of small children and pets. Never allow children to operate the
DR POWERWAGON 5.0. Never carry children, adults or pets in the DR
POWERWAGON 5.0. Use caution when another person approaches.
Keep your hands away from the belt and pulleys while the engine is running.
ALWAYS shut off the engine and remove the spark plug wire before adjusting the
machine.
Do not use the DR to drag or tow items.
The exhaust area on the engine becomes very hot with use. Allow the engine to cool
before doing maintenance or making adjustments.
Keep combustible substances away from the engine when it is hot.
When operating over uneven terrain and slopes, use EXTREME CAUTION to ensure
solid and firm footing.
Use 1
st
gear with loads over 300 lbs. and on slopes.
Never use your machine on slopes greater than 20°.
Use the DR POWERWAGON 5.0 only in daylight or good artificial light.
Use extra caution when operating in wet or slippery conditions.
Always operate the DR POWERWAGON 5.0 from behind the handlebars, never
from the side.
DR POWERWAGON 5.0 Safety & Operating Instructions 4
While using the DR POWERWAGON 5.0, don't hurry or take things for granted.
T
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.
Use caution when moving downhill and braking. Apply the parking brake slowly to
avoid tipping forward.
Do not overload the DR POWERWAGON 5.0. 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.
The maximum load is 500 lbs. on level terrain.
When shifting to reverse, be careful to avoid tipping as the swivel wheel changes
direction.
Do not rev the engine. Excessive speed or tampering with the governor can be
dangerous. Operate the machine in the lowest gear that is satisfactory to do the job.
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 5.0 at a moment's notice.
Never allow people who have not read these instructions to use the DR
POWERWAGON 5.0.
Do not operate the machine when under the influence of alcohol or medication.
Watch for traffic when operating near roadways.
Safety with Gasoline-P ow ered Machines
WARNING!
POWERWAGON 5.0 running smoothly and, most importantly, prevent injury to
yourself or others. Please review them carefully before starting your machine.
Do not run the engine in an enclosed area or without proper ventilation.
Store all fuel in containers specifically designed for this purpose.
Fill the gasoline tank outdoors with the engine off. Don't handle gasoline if you or
anyone nearby is smoking, or if you're near anything that could cause it to ignite or
explode.
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 in any enclosure. Never store the
machine near an open flame or spark with gas in the tank.
Do not change the engine governor settings or modify the engine speed.
he items listed in this section will help you keep your DR
5 DR POWERWAGON 5.0 Safety & Operating Instructions
A Note to All 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.
Any DR POWERWAGON 5.0 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 Informa tion and P otential 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.
DR POWERWAGON 5.0 Safety & Operating Instructions 6
Chapter 3: Setting Up Y our DR POWERWAGON 5.0
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 5.0 by reviewing the picture on this page before beginning the
steps outlined in this chapter.
DR POWERWAGON 5.0 Controls and F ea tures
Molded Body
Removable
Tool Tray
Dump Lever
Parking
Brake
Lever
Throttle
Shift
Lever
Key Switch
Operator
Presence
Lever
Wheel Clutch Lever
Manual
Recoil
(not shown)
Fuel & Oil
Reservoirs
All-Terrain Tires
7 DR POWERWAGON 5.0 Safety & Operating Instructions
Battery
Figure 1
Unpacking the DR POWERWA GON 5.0
w
Tools & Supplies Needed:
Screwdriver
Hammer
Knife
Gloves
Eye protection
Metal shears
WARNING! Al
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. Pry off the fasteners and cut any ties holding the machine to the pallet.
4. Roll the DR POWERWAGON 5.0 off the pallet. Do not discard your pallet and
packaging material until you are fully satisfied with your machine.
ays wear eye protection when cutting the banding. The
WARNING! Be sure to fill your engine with oil and gas before use in
accordance with the
Safety & Operating Instructions.
Check the Tire Pressure
The recommended tire pressures are listed below.
All-Terrain Tires 10-14 lbs.
Turf Tread Tires 14-28 lbs. (optional accessory, sold separately)
Swivel Tire 30-50 lbs.
Note: The heavier the load, the higher the tire pressure should be. Do not go above the
maximum recommended load or pressure.
DR POWERWAGON 5.0 Safety & Operating Instructions 8
Adding Oil and Gasoline
2
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 the correct fill.
WARNING! You must add oil before starting the engine. This
machine is 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.
Important! To get an accurate reading when checking the oil level:
⇒ The machine should be on a level surface.
⇒ The dipstick should be screwed down on Briggs & Stratton engines.
Engine Oil Capacity
Briggs & Stratton Quantum 5.0 16-22 oz. (0.45-0.63L)
Use only SAE 30 high detergent oil. Other types of oil could cause problems operating
your machine. Please refer to your engine manufacturer’s 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
Fuel Fill
initially add 16 oz. (½ 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
Oil Fill
careful not to overfill. (Figure 2)
3. Fill the gas tank to within ¼ inch of the top
with fresh, unleaded gas. See your engine
manufacturer’s owner’s manual for more
information.
Figure
9 DR POWERWAGON 5.0 Safety & Operating Instructions
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