DR POWERWAGON 5.0, Operating Instructions Manual

Page 1: ...DR POWERWAGON 5 0 Safety Operating Instructions Please read instructions before operating the DR POWERWAGON 5 0...

Page 2: ...p 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 do...

Page 3: ...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 T...

Page 4: ...le so we can help you quickly Conventions used in this manual 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 spec...

Page 5: ...e 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...

Page 6: ...3 DR POWERWAGON 5 0 Safety Operating Instructions 153441 153431 180531...

Page 7: ...n 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 th...

Page 8: ...ON 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...

Page 9: ...ce 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 informa...

Page 10: ...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...

Page 11: ...your pallet and packaging material until you are fully satisfied with your machine Check the Tire Pressure The recommended tire pressures are listed below All Terrain Tires 10 14 lbs Turf Tread Tires...

Page 12: ...ded 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 t...

Page 13: ...DR POWERWAGON 5 0 Safety Operating Instructions 10 Connect the Battery Wires Connect the red wires to each other Figure 3 The black wires are connected at the factory Figure 3 Connect the red wires...

Page 14: ...th an Operator Presence Control for added safety The Operator Presence Lever must be depressed whenever the Shift Lever is in gear or the engine will stop You may run the engine without depressing the...

Page 15: ...ual for information on cold weather starting Operating The DR POWERWAGON 5 0 has a four speed forward transmission and single speed reverse Use the lower gears for slower speeds heavy loads or more po...

Page 16: ...oad evenly so your DR POWERWAGON 5 0 will be as stable as possible Don t pile material too high Divide your load and make several lighter trips Do not pile heavy loads such as rocks or gravel to a hei...

Page 17: ...r load in the bed to limit the shifting of the load on slopes The higher and heavier the load the greater the possibility of tipping over Travel up and down slopes Figure 8 and avoid going across slop...

Page 18: ...Figure 10 2 After unloading push the bed back down into place by hand Note The bed of the DR POWERWAGON 5 0 is balanced so you can dump the load with minimal effort If you are carrying a very heavy l...

Page 19: ...considered maximum under normal operating conditions Increase the frequencies under extremely dirty or dusty conditions Procedure Before Each Use Every 25 Hours Every 100 Hours Check Operator Presence...

Page 20: ...ngine must be operated for at least 45 minutes to maintain proper battery charge If the battery loses its charge you ll need to use a trickle charger like the DR Battery Charger to recharge it The cha...

Page 21: ...l bracket and one toward the center of the wheel Figure 11 Grease these two fittings with 2 lithium grease to keep the wheel spinning freely at least every 25 hours of operation per the Maintenance Ch...

Page 22: ...and drain the oil 2 Replace the plug and refill the oil to the level indicated on the dipstick Do not overfill Refer to the Adding Oil and Gasoline section on page 9 Alternate Method 1 Remove the Oil...

Page 23: ...slide the belt from the idler arm and clutch pulley Figure 16 6 Remove the belt from the transmission pulley at the front of the machine Figure 17 7 Remove the belt from the drive pulley under the en...

Page 24: ...d adjust the guides as necessary and tighten the guide bolts Figure 16 with the 9 16 socket Note When the clutch lever is released disengaged the belt guides will just touch the belt Figure 19 to prev...

Page 25: ...l off 3 To replace the wheel leave the key in place if possible and slide the wheel back on If the key comes out when you take the wheel off put the wheel back on and rotate it until the key slots lin...

Page 26: ...transaxle Figure 21 1 4 turn clockwise with the 1 2 wrench to tighten the parking brake Test the parking brake as described in Steps 1 3 Repeat the adjustment if necessary 5 If you can t get the parki...

Page 27: ...ools Supplies Needed 1 2 wrench or socket Mat or container for loose parts Note You may want to remove the wheel to provide easier access to the parking brake area See page 21 1 Find a level area to w...

Page 28: ...l the brake disc 5 Replace the caliper housing and its parts two actuator pins the backing plate and the second brake pad Figure 25 Make sure the brake arm assembly is in the upright position Be sure...

Page 29: ...clamp with the screwdriver so the throttle cable can slide below it It is not necessary to remove the clamp Figure 26 2 Remove the Z bend end of the cable from the throttle plate Figure 26 3 Remove th...

Page 30: ...cable goes into the smaller hole Place the throttle cable sheath under the cable clamp Figure 26 8 Make sure that the throttle plate is all the way back to the stop position It will normally retract t...

Page 31: ...Figure 31 4 Loosen the lock nut on the shift tie rod end with the 9 16 open end wrench Figure 31 and turn the tie rod end clockwise to shorten the tie rod and counterclockwise to lengthen it 5 Adjust...

Page 32: ...nut on the underside threaded of the bracket by 1 8 to 1 4 and tightening the nut on the outside against the bracket Check the tension on the clutch lever and repeat the adjustment as needed 3 If the...

Page 33: ...ole Replace the plug and pull the recoil starter rope until you feel strong resistance This will coat the piston and seat the valves to prevent moisture buildup Clean replace the air filters Clean dir...

Page 34: ...n or jammed Call 1 800 DR OWNER 376 9637 for assistance The engine won t start manually Please refer to the engine manufacturer s owner s manual for engine specific procedures Is the key in the RUN po...

Page 35: ...attery may need to be periodically charged See the Battery Care section on page 17 If your battery is charged and your DR still won t start call 1 800 DR OWNER 376 9637 for assistance The engine lacks...

Page 36: ...ey groove may be nicked Check the belt for wear and hard spots File off any nicks on the pulley Check the belt guide alignment See page 21 The belt may be stretched Replace it Machine is hard to get i...

Page 37: ...DR POWERWAGON 5 0 Safety Operating Instructions 34 Notes...

Page 38: ...35 DR POWERWAGON 5 0 Safety Operating Instructions Notes...

Page 39: ...ransportation charges if required During the warranty period warranty parts will be shipped by standard method at no charge to the warranty holder Expedited shipping of warranty parts is the responsib...

Page 40: ...r according to the dipstick with SAE30 High Detergent HD motor oil GAS Fill the gas tank with fresh unleaded gasoline ENGINE It is very important to keep the engine clean Remove grass and other debris...