DK5000E Generator Parts Manual

EMB Manufacturing Inc.
4144 Boomer Line · St. Clements, On · N0B 2M0 · Canada
Ph: (519) 699-9283 · Fax: (519) 699-4146
www.embmfg.com
DK5000E
Generator Parts Manual
Starting with S/N’s
#DK50001
Refer to the operators
manual for safe
operation and
maintainance
RevA 170314
DK5000E Parts Manual
WALLENSTEIN by EMB Mfg.
Foreword
EMB Mfg. has prepared this parts manual to assist customers in ordering quality OEM replacement parts.
Proper and regular service and replacing old, worn or broken parts with the correct Wallenstein parts are essential to prolonging the life of your Wallenstein product. Please refer to this manual before ordering any replacement parts.
All information contained in this parts manual is based on the latest product specification available at the time
of printing this manual. If your product differs from the specifications contained within this manual contact EMB
Mfg. for information.
EMB reserves the right to alter specifications on their products at any time.
Reproduction of this parts manual of any kind is prohibited without prior written permission from EMB Mfg.
For parts and information please contact your dealer. If your dealer is no longer availalble please go to our
website: http://www.embmfg.com and click on ”FIND A DEALER NEAR YOU” for information on a local dealer.
Page 2
Rev A 170314
DK5000E Parts Manual
WALLENSTEIN by EMB Mfg.
Table of Contents
Bolt Torque.................................................................. 4
Main Assembly........................................................... 5
Frame & Engine / Generator Assembly������������������ 6
Control Panel.............................................................. 7
DK5000E Wiring Diagram........................................... 8
Label Layout................................................................ 9
Accessories............................................................... 10
Alternator:
Mecc Alte Inc. S16W-###/#
Below are alterantor parts availalble from Wallenstein.
For other parts and maintenance or repair information please refer to the
Mecc Alte alternator manual that shipped with the generator.
1 Non Drive End Bracket
390302209
2 Fan
392000015
3 Rear Bearing 6203-2ZC3
390302521
4 Diode
9910356050
5 Varistor
9910384005
6 Capacitor # :see chart below
GECAP14MF 14 MF CAPACITOR
Find the value of the capacitor in
GECAP16MF 16 MF Capacitor
your alternator, and match it to the
GECAP18MF Capacitor, 18 MFZ
list shown here for the correct order
GECAP20MF Capacitor 20MFZ
part number.
GECAP25MF Capacitor 25MFZ
GECAP31MF Capacitor, 31.5 MFZ
GECAP35MF 35 MF CAPACITOR
GECAP40MF 40 MF CAPACITOR
Alternator maintenance should be
performed by trained personel only.
Exercise extreme
caution when working
with exposed wiring
of the alternaotor,
be aware that high
voltage discharge
of the capacitor is a
danger.
Page 3
Rev A 170314
DK5000E Parts Manual
WALLENSTEIN by EMB Mfg.
Bolt Torque
CHECKING BOLT TORQUE
The tables shown below give correct torque values for various bolts and capscrews. Tighten all bolts to
the torques specified in chart unless otherwise noted. Check tightness of bolts periodically, using bolt
torque chart as a guide. Replace hardware with the same strength bolt.
ENGLISH TORQUE SPECIFICATIONS
Bolt Torque*
Bolt
SAE 5
SAE 2
SAE 8
Diameter
(N.m) (lb-ft) (N.m) (lb-ft) (N.m) (lb-ft)
"A"
1/4"
5/16"
3/8"
7/16"
1/2"
9/16"
5/8"
3/4"
7/8"
1"
8
13
27
41
61
95
128
225
230
345
6
10
20
30
45
60
95
165
170
225
12
25
45
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
METRIC TORQUE SPECIFICATIONS
Bolt Torque*
Bolt
10.9
8.8
Diameter
(N.m)
(lb-ft)
(N.m) (lb-ft)
"A"
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
148
229
450
774
1550
2710
Torque figures indicated above are valid for non-greased or non-oiled threads and heads unless otherwise specified. Therefore, do not grease or oil bolts or capscrews unless otherwise specified in this
manual. When using locking elements, increase torque values by 5%.
* Torque value for bolts and capscrews are identified by their head markings.
Page 4
Rev A 170314
Page 5
18
3
See Frame &
Engine / Generator
Assembly
10
Main Assembly
17
13
16
5
11
8
14
9
7
2
12
15
4
6
1
BOM ID
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Description
Assembly, DK5000E Panel
Fuel Tank, HD Style
Alternator, 4.9 kVA
Offset Plate, Hatz Diesel
Kohler Diesel Mounting Bracket
Box Connector, 3/8
Hex Bolt, 5/16NC x 3/4
Hex Bolt, 3/8NC x 1-3/4
Hex Lock Nut, 5/16NC
Hex Lock Nut, 3/8NC
Flat Washer, 3/8
Self-tapping Screw #10
Hose Clamp, #4
Rubber Mount
Fuel Cap - Diesel
Fuel Shut-off, 1/4"
Fuel Line, 1/4" ID x
Kohler KD350 Taper Shaft
See Control Panel
Assembly
Part Number
4042A001
4042W001
Z65404
4041L101
4042L102
Z62261
Z71207
Z71317
Z72221
Z72231
Z73131
Z76712
Z79405
Z79931
Z93106
Z93301
Z93315
Z47507
Qty
1
1
1
1
1
1
1
2
9
2
2
8
6
4
1
1
3
1
DK5000E Parts Manual
WALLENSTEIN by EMB Mfg.
Rev A 170314
Page 6
38
BOM ID
19
20
21
22
23
24
25
26
27
28
29
39
30
Description
0391802005
4015W501
4042L103
4042L105
GES16COVER2
Z47507
Z62711
Z62821
Z65404
Z71374
Z72211
22
32
20
Description
Plastic Cap
Main Frame, EU/GF Style
Keyswitch Bracket, KD350
Tray, HD Battery
Blind Cap Lid
Kohler KD350 Taper Shaft
Grounding Terminal, 6-14
Rubberized Wire Clamp, 5/8"
Alternator, 4.9 kVA
Hex Bolt, 3/8NF x 1
Hex Lock Nut, 1/4NC
Qty
1
1
1
1
1
1
1
1
1
4
1
Frame & Engine / Generator Assembly
19
BOM ID
30
31
32
33
34
35
36
37
38
39
25
Description
Z72752
Z72211
Z72921
Z73101
Z77532
Z77551
Z78301
Z78303
Z93202
Z93207
27
23
Description
Machine Nut, #10-32NF
Rubber Flat Washer, 5/16 x 0.093"
Wing Nut 1/4NF
Flat Washer, #10
SHCS, M6x1.0x18mm
SHCS, M8x1.25x18mm
Machine Screw, 1/4-20NC x 3/4
Machine Screw, #10-32NF x 1/2
J-Hook 1/4 x 7
Hold-Down Strap, 1 x 8-1/2
Alternator:
Mecc Alte Inc. S16W-150/A
See parts chart page 3
For maintenance or repair information
please refer to the Mecc Alte alternator
manual that shipped with the generator.
Engine:
349 cc Kohler KD350
For maintenance or repair information
please refer to the Kohler Engine manual
that shipped with the generator.
Qty
4
4
2
4
1
1
1
7
2
1
28
35
24
31
36
34
33
21
37
35
Keyswitch Support
Detail View
26
29
37
34
21
DK5000E Parts Manual
WALLENSTEIN by EMB Mfg.
Rev A 170314
Page 7
BOM ID
37
38
39
40
41
42
43
44
45
46
Control Panel
Part Number
4042L107
Z62612
Z62614
Z62621
Z63403
Z63404
Z63408
Z66110
Z66211
Z78304
Description
Panel, DK Style
Popout Breaker, 20A
Popout Breaker, 30A
Main Switch Breaker, 20A
Recp., 30A 125/250V L14-30
Recp., 30A 125V L5-30
Recp., 20A 125V GFCI 5-20R
Toggle Switch, Three Pole
Generator Load Monitor, 2750W
Machine Screw, #6-32NC x 3/8
40
41
42
39
38
Qty
1
2
1
1
1
1
2
1
1
14
44
43
45
46
37
DK5000E Parts Manual
WALLENSTEIN by EMB Mfg.
Rev A 170314
Page 8
DK7300E
30 amp Main
Switch Breaker
X
Y
#11
Black
XN
#12
YN
Generator
Black
DK5000E
20 amp Main
Switch Breaker
4 Pin Plug
Panel end
(insert view)
4 Pin Plug
Generator end
X
Y
DK5000E Wiring Diagram
#5
White (XN)
#21
White
#9
Black
#27
#1
Green
Black
#4
3
2
1
6
5
4
9
8
7
Alternator
Ground
#2
#13
Green
#26
#2
#25
Green
Ground
#8
#7
White (T1)
#22
White
20A 125V
GFCI 5-20R
Black
#17
Popout
Breaker,
30A
White (T6)
30A 125V
L5-30
#15
White
#14
Black
Black
Black
Green
#23
Black
#3
3PDT
Toggle Switch
30A 125/250V
L14-30
Black
#10
#1
Black
#6
Black
Neutral
#3
White (XN)
#20
White
#4
#16
White (T6)
#24
Green
20A 125V
GFCI 5-20R
Popout
Breaker,
20A
Black
#18
#21
White (XN)
White (T1)
Black
#19
Popout
Breaker,
20A
Note: white (T1) wire must
pass thru Power Module in
the opposite direction of
white (T6) and white (XN)
for module to function
properly.
DK5000E
#Z66211
DK7300E
#Z66212
Power
Monitor
Module
DK5000E
To accessory port
inside key switch
DK7300E
Splice into red/white
key switch wire.
12v +
Red
12v Black
To 12v DC
ground post
(separate from
AC ground
post on
electrical panel
housing)
Description
Battery
Pos 32" #Z62316
WireCable,
Harness
Battery Cable, Neg 20"
DK Series Generator Bundle
Kohler KD350 Engine Electrical:
Please refer to the Kohler Engine manual
that shipped with the generator.
Part Number
Z93211
Z93208
Z62316
DK5000E Parts Manual
WALLENSTEIN by EMB Mfg.
Rev A 170314
Page 9
#######
BEARING
S
KG
RPM
AMPS
#######
S1
1
Serial Label
EMB MFG INC
4144 BOOMER LINE, ST CLEMENTS, ON N0B 2M0
PH: 519-699-9283 FAX: 519-699-4146
J
H
II/I
IP 21
INS.
CONNECTION
####/####
.#####
####
SERVICE
PHASE
www.embmfg.com
#### #####
HZ 60
1
COSPHI
120/240
CODE
KVA #.# V
##########
ALTERNATOR
TYPE
LR####
!
SERIAL NUMBER
Employer seulemer DEHORS
et loin de fenêtres, des porte
et des ventilateurs.
N'employerJAMAIS dans la
maison ou dans des secteurs
partiellement inclus tels que des
garages, MÊME SI les portes et
les fenetres soient ouvertes.
MODEL
Only use OUTSIDE and far
away from windows, doors,
and vents.
NEVER use inside a home or
garage, EVEN IF doors and
windows are open.
L'utilisation d'un générateur à l'intérieur PEUT VOUS FAIRE MOURIR
EN MINUTES. L'échappement contient le monoxyde de carbone,
Ceci est un toxique que vous ne pouvez ni voir ni sentir.
Using a generator indoors CAN KILL YOU IN MINUTES. Generator
Exhaust contains carbon monoxide. This is a poison you cannot see
or smell.
DANGER!
Label Layout
Z94227
Attention!
Z94655
Two Sides
Cette génératrice au diesel a été conçue pour
fonctionner à régime modéré ou élevé. Un
fonctionnement à régime moyen ou sans charge
entraînera, à terme, la carbonisation et la défaillance du
moteur. Le contrôleur de puissance enregistre les états
de sous-charge et les signale au moyen d'un témoin
rouge. Faute d'augmenter la charge pour atteindre le
régime de fonctionnement optimal, la garantie sera
annulée. Bien lire le manuel du propriétaire.
Z94227
This diesel generator is designed to operate at
moderate to high load. Operating at medium to no
load will cause carbonizing and eventual engine
failure. The Power Monitor feature will log and
indicate (red indicator) under-load conditions.
Failure to increase to optimum load requirements
will void the warranty. Read the owners manual.
Z94800
DK5000E Parts Manual
WALLENSTEIN by EMB Mfg.
Rev A 170314
DK5000E Parts Manual
WALLENSTEIN by EMB Mfg.
Accessories
Call your dealer for pricing and availability
#Z93204 U1 250CCA Lawn & Garden Battery
The perfect battery to reliably get your generator
started.
#Z93204
#WK210 TWO WHEEL KIT WITH 10'' TIRES
#WK214 TWO WHEEL KIT WITH 14'' TIRES
#WK214
Shown mounted
on DK7300E
A must have add on kit for true portability!
Kit consist of handles and axle with tires The kit
is easy to install and simply clamps on to the
existing frame.
#Z97077 DK5000E & DK7300E
PORTABLE DIESEL GENERATOR
OPERATOR’S MANUAL
Available as a download at
www.embmfg.com
Page 10
Rev A 170314