Wallenstein DK Series, Operator'S Manual

Page 1: ...519 699 4146 www embmfg com DK5000E DK7300E PORTABLE DIESEL GENERATOR OPERATOR S MANUAL PRINTED IN CANADA REV Feb 2018 PART NUMBER Z97077 Before putting the generator into service Do not attempt to start or operate the DK generator without thoroughly reviewing this manual for safe and proper operation Keep this manual with the DK Generator at all times DK5000E DK7300E ...

Page 2: ...Y 20 4 2 MACHINE COMPONENTS 21 4 2 2 DK5000E 21 4 2 3 DK7300E 21 4 3 MACHINE BREAK IN 22 4 4 PREOPERATION CHECKLIST 22 4 5 CONTROLS 23 4 5 1 DIESEL ENGINE 23 4 5 2 ELECTRICAL CONTROLS 24 4 5 3 FULL POWER FEATURE 24 4 5 4 POWER MONITOR 25 4 6 ELECTRICAL LOAD 26 4 6 1 BALANCING LOADS 26 4 6 2 WATTAGE AND LOAD 26 4 6 3 CALCULATING LOAD 26 4 6 4 WATTAGE CHART 27 4 7 FIELD OPERATION 28 4 7 1 PREPARE 28...

Page 3: ...s website For service contact your local engine dealer Under no circumstances will the manufacturer be liable for any consequential damage or expense of any kind including loss the maintenance of the product This warranty is extended only to the original purchaser and is not transferable Warranty is void if repairs are attempted by anyone other than a Wallenstein Authorized Service Centre ized dea...

Page 4: ...________________________ Customer s Name _________________________________________ Contact Name _________________________________________ Dealer Name _________ _______________________________ Phone Number _________________________________________ Serial Number __________ __________ __________ Delivery Date I have thoroughly instructed the buyer on the equipment care adjustments safe operation and ...

Page 5: ...re three different types of labelling safety informative and product labels Safety Labels are pictorial and always with a yellow back ground colour and generally 2 panel The top panel shows the safety alert the potential hazard and the bottom panel shows the message how to avoid the hazard Informative Labels are generally pictorial have a white back ground colour and can vary to the number of pane...

Page 6: ... x 30 amp 120 240v twist lock L14 30 receptacle 1 x 30 amp 120v twist lock L5 30 receptacle 2 x 20 amp 120v GFCI 15 20R ground fault receptacles Electronic Power Monitor Display cycles between power P kW and total running hours and is capable of displaying frequency C hertz Indicator light warns of underload condition flashing display indicates overload Full Power Feature when the 240V leg is not ...

Page 7: ...83 or Fax 519 699 4146 DANGER Indicates an imminently hazardous situation that if not avoided will result in death or serious injury This signal word is to be limited to the most extreme situations typically for machine components which for func tional purposes cannot be guarded WARNING Indicates a potentially hazardous situation that if not avoided could result in death or serious injury and incl...

Page 8: ... injury or death It is the owners responsibil ity to the operator to ensure familiarity and understanding of the machine DO NOT modify the equipment in any way Unauthorized modification may impair the function and or safety and could affect the life of the equipment DO NOT risk injury or death by ignoring good safety practices DO review safety related items annually with all personnel who will ope...

Page 9: ...ions and of how it works Review the safety instructions with all users annually 5 This equipment is dangerous to children and persons unfamiliar with its operation The operator should be a responsible properly trained and physically able person familiar with machinery and familiar with this equip ment s operations If the elderly are assisting with work their physical limitations need to be recogni...

Page 10: ...bly or using to acquaint yourself with the machine If this machine is used by any person other than yourself or is loaned or rented it is the machine owner s responsibility to make certain that the operator prior to using Reads and understands the operator s manuals Is instructed in safe and proper use of the equipment Understands and knows how to perform the safe condition procedure Flip main swi...

Page 11: ...ual Each of the Safety Messages found on the safety signs on the engine and machine 2 Personal protection equipment including safety glasses safety shoes gloves hearing protection are recommended during assembly in stallation operation adjustment maintaining repairing removal cleaning or moving the generator Do not al low long hair loose fitting clothing or jewellery to be around equipment 3 PROLO...

Page 12: ...e and can be very difficult to extinguish 1 Allow the engine to cool if the generator has been in operation 2 Refuel only outdoors in a well ventilated area with the engine off 3 Never smoke near diesel and keep other flames and sparks away 4 Do not overfill the fuel tank 5 Always store diesel in an approved container Make sure that any spilled fuel has been wiped up before starting the engine 2 5...

Page 13: ...be around this machine 11 Plug appliances directly into generator or use a heavy duty outdoor rated extension cord Make sure entire extension cord is free of cuts or tears and the plug has all 3 prongs espe cially a grounding pin 12 If necessary to connect generator to house wiring to power appliances have a qualified electrician install appropriate equipment Or your utility company may be able to...

Page 14: ...terials 7 With the engine and exhaust system cool cover the generator to keep out dust 8 Do not use a nonporus sheet as a dust cover A nonporous cover will trap moisture around the generator promoting rust and corrosion 2 11 ELECTRICAL SAFETY 1 The generator produces enough electric power to cause a serious shock or electrocution if misused 2 Using a generator or electrical appliance in wet condit...

Page 15: ...y result in injury 13 DO NOT operate engine with an accumulation of grass leaves paper or other combustible materials in the muffler area 14 DO NOT use this engine on any forest covered brush covered or grass covered unimproved land unless a spark arrester is installed on the muffler The arrester must be maintained in effective working order by the operator Canada check with local provincial or fe...

Page 16: ... else to use this generator until such information has been reviewed Annually review this information before the season start up Make these periodic reviews of SAFETY and OPERATION a standard practice for all of your equipment We feel that an untrained operator is unqualified to use this machine A sign off sheet is provided for your record keeping to show that all personnel who will be working wit...

Page 17: ...g the generator indoors Caution A generator produces enough electrical power to cause serious shock or electrocution Using a generator in wet conditions such as in rain or snow or with wet hands could result in elec trocution Keep the generator dry Caution do not refuel the machine while smoking or when near open flame or sparks Fuel is highly flamma ble handle with care Caution read and understan...

Page 18: ...lure to increase to optimum load re will void the warranty Read the owners Cette génératrice au diesel a été c fonctionner à régime modéré ou fonctionnement à régime moyen ou entraînera à terme la carbonisation et la d moteur Le contrôleur de puissance enreg de sous charge et les signale au moyen rouge Faute d augmenter la charge pou régime de fonctionnement optimal la g annulée Bien lire le manue...

Page 19: ...and place in your pocket and wait for all mov ing parts to stop before servicing adjusting or repairing To prevent electrical shocks do not operate this generator in the rain or with wet hands Generatorshouldbekeptdryandnotoperated on wet or damp surfaces Close and secure all guards deflectors and shields before starting and operating Do not connect the generator to a commercial power line Do not ...

Page 20: ...2 Use a battery carrier to lift the battery or place hands at opposite corners to avoid spilling acid through the vents 3 Avoid contact with battery electrolyte External Contact Flush immediately with water Eye Contact Flush with water for 15 minutes Get prompt medical attention Clean up any spilled electrolyte immediately 4 Avoid contact with battery posts terminals and related accessories they c...

Page 21: ...nted on the end of the frame for convenient access and opera tion The unit is designed to provide electrical power for work or home or provide power at a remote location Each outlet is designed with a circuit breaker to protect against overload The machine is neutral bonded to the frame The battery and fuel tank are mounted in the frame for convenient access Kohler KD350 4 9kVa Alternator 250 CCA ...

Page 22: ... checklist is provided for the opera tor It is important for both the personal safety and maintaining good mechanical condition that this checklist is followed Before operating the Wallenstein Portable Gener ator and each time thereafter the following areas should be checked off Pre Operation Checklist P Check and lubricate the machine per the schedule outline in the Maintenance Section Exhaust ga...

Page 23: ...event engine damage caused by an insuf ficient amount of oil in the crankcase Before the oil level in the crankcase can fall below a safe limit the system will automatically stop the engine Oil Alert Kubota The Oil Alert system is designed to prevent en gine damage caused by an insufficient amount of oil in the crankcase Before the oil level in the crankcase can fall below a safe limit the Oil Ale...

Page 24: ... details of the generator see Power Monitor section B C D E F IMPORTANT A circuit breaker that trips repeatedly may indicate a problem H G A 4 5 3 FULL POWER FEATURE The DK Series alternator is equipped with two windings each delivers 120v When the voltage selector switch is in the 120V 240V position the power circuits legs operate in series like two separate generators Each leg supplies half the ...

Page 25: ...haust and eventual engine failure The Power Monitor feature will help avoid costly engine repairs due to carbonizing damage caused by running in underload is not covered by warranty The Power Monitor will indicate under load conditions alert ing the user to increase to optimum load requirements Additional functions of the monitor include log and display the number of running hours and log the numb...

Page 26: ...g watts at start up In other words wattage will spike at starting and level off to running continuous wattage when it is operating normally See wattage chart Resistive Load A resistive load is lighting hot plate TV etc Resistive loads generally will not spike and start ing wattage is the same as running wattage See wattage chart Continuous Wattage Continuous wattage is the wattage range that can b...

Page 27: ...00 Television tube 43 flat screen 300 190 300 190 Drill 3 8 4 amps 600 440 Air Conditioner 10000 BTU 2200 1500 Drill 1 2 5 4 amps 900 600 Laptop Computer 200 250 200 250 Desktop Computer 600 800 600 800 Farm Equipment Approx Starting Running Monitor LCD style 30 30 Electric Fence 25 miles 250 Printers Milk Cooler 1800 1100 Ink Jet Ink Jet Multi Function 20 250 20 250 Milker Vacuum Pump 2hp 2300 10...

Page 28: ...justing or repairing To prevent electrical shocks do not operate this generator in the rain or with wet hands Generatorshouldbekeptdryandnotoperated on wet or damp surfaces Close and secure all guards deflectors and shields before starting and operating Do not connect the generator to a commercial power line Do not operate with damaged or defective ex tension cords or power cords Protect the cord ...

Page 29: ...Use properly rated grounded 3 prong extension cords tools and appli ances b Do not operate at temperatures above 100 F 40 C to prevent overheating of the engine or generator Always run for a few minutes without an electrical load to help cool the components before shutdown 6 Electrical Loads The generator is ideally suited to camping boating farm household workshop con struction site or anywhere t...

Page 30: ...ating Hints Position frame on a level area to minimize the chance of spilling fuel and maximize the fuel capacity of the tank Spilled fuel can be ignited by a spark from the electrical power system Do not refuel while the engine is running Wait until the unit has cooled before refuelling Keep the working area neat and clean to pre vent slipping and tripping Prevent accidents at the work site Alway...

Page 31: ... with 10 tires WK210 or 14 tires WK214 5 1 MOVING Wheel Kit 4 7 3 RESIDENTIAL The most economical way to supply power during a power outage is to use a portable generator and run extension cords into the house to power chosen appliances Never connect a generator to a house electrical system without a transfer switch Known as backfeed ing it is both illegal and extremely dangerous A safer system is...

Page 32: ...in a cool dry area on wooden blocks or a wooden pallet Charge it monthly to maintain an adequate charge 9 Store the machine inside in cool dry area Avoid storage areas with high humidity because that promotes rust and corrosion 10 Use a canvas tarp or similar material to keep it covered and free of dust Avoid plastic or non porus cover that will trap moisture and promote corrosion 11 If stored out...

Page 33: ...efficiency only if clean lubricants are used Use clean containers to handle all lubricants Store them in an area protected from dust moisture and other contaminants Never work under equipment unless it is blocked securely A fire extinguisher and first aid kit should be kept readily accessible while performing maintenance on this equipment Periodically tighten all bolts nuts and screws and check th...

Page 34: ...epair it To ensure the best quality and reliability use only new genuine parts for repair and replacement Genuine factory replacement parts must be used to restore your equipment to original specifications The manufacturer will not be responsible for injuries or damages caused by use of unapproved parts and or accessories 6 2 1 GENERAL MAINTENANCE On a regular basis check all nuts bolts and screws...

Page 35: ...4 Connect positive lead of charger to positive terminal and negative lead to negative terminal 5 Charge battery according to the instructions from battery charger manufacturer and battery manufacturer Jump Starting Battery Read Section 2 9 on battery safety for safe handling of the battery Unit used for jump starting should have a 12 volt battery and a negatively grounded system 1 Connect positive...

Page 36: ...gth width height Inch cm 29 25 x 20 25 x 23 75 74 3 x 51 5 x 61 0 31 5 x 21 0 x 23 75 80 0 x 53 5 x 61 0 Starting System electric start electric start Warranty Residential Commercial 3 YR 3 YR Receptacles 1 x L14 30 1 x L5 30 2 x GFCI15 20R 1 x L14 30 1 x L5 30 2 x GFCI15 20R Options Details WK210 WK214 Wheel Kits Kohler KD350 Low oil shutdown Kubota OC95 E3 Low oil alert Full Power Feature when t...

Page 37: ... 72 110 155 215 390 570 850 9 19 33 53 80 115 160 290 420 630 17 36 63 100 155 220 305 540 880 1320 12 27 45 75 115 165 220 400 650 970 8 8 N m lb ft Bolt Torque Bolt Diameter A 10 9 N m lb ft M3 M4 M5 M6 M8 M10 M12 M14 M16 M20 M24 M30 M36 5 3 6 10 25 50 90 140 225 435 750 1495 2600 4 2 2 4 7 18 37 66 103 166 321 553 1103 1917 1 8 4 5 9 15 35 70 125 200 310 610 1050 2100 3675 1 3 3 3 7 11 26 52 92...

Page 38: ... for damage replace Ensure machine is off Breaker tripped Reset breaker check reason for breaker trip replace if defective Ensure machine is off Alternator problem check connections to control panel inspect alternator Ensure machine is off Call technician Electrical cords damaged cut Check cord and connections for damage replace Ensure machine is off Broken receptacle Check receptacle and connecti...

Page 39: ...Lawn Garden Battery For models DK5000E DK7300E The perfect battery to reliably get your generator started Z93204 WK214 Shown mounted on DK7300E WK210 TWO WHEEL KIT WITH 10 TIRES WK214 TWO WHEEL KIT WITH 13 TIRES For models DK5000E DK7300E A must have add on kit for true portability ...

Page 40: ...ON SWITCH 22 IMPROPER MAINTENANCE 33 INSPECTION 4 K KOHLER 22 KUBOTA 22 L LABELING 5 LABELLING INFORMATION 5 LED INDICATOR 24 LUBRICANTS 32 M MAXIMUM WATTAGE 25 MAX POSITION 23 N NOISE 11 O OFF 22 OIL 32 OIL ALERT 22 ON 22 OPERATING HINTS 29 ORIENTATION 6 OVERLOAD 24 P POWER MONITOR 20 R REACTIVE LOAD 25 RESISTIVE LOAD 25 RESPONSIBLE 8 RUNNING CONTINUOUS WATTAGE 25 S SAFE CONDITION 9 10 12 19 27 3...