Kodiak KD5000D Operator's Manual
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Kodiak KD5000D Operator's Manual

Portable diesel generator
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KD5000D & KD7300D
PORTABLE DIESEL GENERATOR
OPERATOR'S MANUAL
Do not attempt to start or operate the KD generator without
thoroughly reviewing this manual for safe and proper operation.
Keep this manual with the KD Generator at all times
PRINTED IN CANADA
REV 111113
John Brooks Company Limited
2625Meadowpine Blvd, Mississauga
ON. L5N 7K5 Canada
Tel 905 567 6590 Fax 905 567 4330
www.dynablast.ca
KD7300D
Before putting the generator into service:
U1 Lawn & Garden 250 CCA battery is not included
EMB MFG INC.
BY
KD5000D
PART NUMBER: Z97082

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  • Page 1 ON. L5N 7K5 Canada Tel 905 567 6590 Fax 905 567 4330 www.dynablast.ca KD5000D KD7300D KD5000D & KD7300D PORTABLE DIESEL GENERATOR OPERATOR'S MANUAL Before putting the generator into service: Do not attempt to start or operate the KD generator without thoroughly reviewing this manual for safe and proper operation.

  • Page 2: Table Of Contents

    SERVICInG THE BATTERY ....35 4.1.1 SAFE ConDITIon .........19 SPECIFICATIONS ........36 4.1.2 InSTALL BATTERY: .........20 MECHAnICAL......... 36 MACHInE CoMPonEnTS ......21 KD5000D ............36 4.2.2 KD5000D ..........21 KD7300D ............36 4.2.3 KD7300D ..........21 BoLT ToRQUE ........37 MACHInE BREAK-In ......22 TROUBLE SHOOTING ......

  • Page 3: Warranty

    Warranty WARRANTY This product is warranted to be free of defects in materials and workmanship under normal use and service, for a period of three years from the date of purchase, when operated and maintained in accordance with the operating and Maintenance Instructions supplied with this unit. This warranty does not cover misuse or negligence.

  • Page 4: Kd Series Portable Diesel Generator

    Kodiak KD SERIES PORTABLE DIESEL GENERATOR DELIVERY INSPECTION REPORT To activate warranty, register your product online at www.kodiakpower.ca _________________________________________ Pre-Delivery Inspection Customer’s name  Inspect for damage from shipping, immediately contact the shipping company if damage is found. _________________________________________ Portable Diesel Generator...

  • Page 5: Serial Number Location

    LABELLING INFORMATION As you begin to get familiar with your Kodiak product, you will notice that there are numerous labels lo- cated on the machine. Here is a brief explanation of what they are for and how to read them.

  • Page 6: Introduction

    Use the Table of Contents or Index as a guide to locate required information. Keep this manual handy for frequent reference and to pass on to new operators or owners. Call your Kodiak dealer or the Distributor if you need assistance, information or additional copies of the manuals.

  • Page 7: Safety

    It may also be used to alert against unsafe practices. If you have any questions not answered in this manual or require additional copies or the manual is dam- aged, please contact your dealer or Kodiak: East 1-888-881-6667, west 1-800-527-8592...

  • Page 8: Safety Do's & Don'ts

    YOU are responsible for the SAFE operation • DO have a first-aid kit available for use should and maintenance of your Kodiak Portable Die- the need arise and know how sel Generator. YOU must ensure that you and to use it.

  • Page 9: Equipment Safety Guidelines

    EQUIPMENT SAFETY GUIDELINES Safety of the operator and bystanders is one of the main concerns in designing and developing equip- ment. However, every year many accidents occur which could have been avoided by a few seconds of thought and a more careful approach to handling equipment. You, the operator, can avoid many acci- dents by observing the following precautions in this section.

  • Page 10: Safety Training

    SAFETY TRAINING 5. Know your controls and how to stop the 1. Train all new personnel and review instruc- engine and machine quickly in an emergency. tions frequently with existing workers. Safety Read this manual and the one provided with is a primary concern in the design and manu- your engine.

  • Page 11: Preparation

    PREPARATION 4. Clear working area of stones, branches or 1. never use the engine and machine until the hidden obstacles that might be hooked or operators have been adequately trained in the snagged, causing injury or damage. safe operation of the machine and have read and completely understand: 5.

  • Page 12: Maintenance Safety

    MAINTENANCE SAFETY 1. Good maintenance is your responsibility. Poor 8. where replacement parts are necessary for maintenance is an invitation to trouble. periodic maintenance and servicing, genuine factory replacement parts must be used to 2. Follow good shop practices. restore your equipment to original specifica- •...

  • Page 13: Operating Safety

    OPERATING SAFETY 1. Please remember it is important that you read 12. If necessary to connect generator to house and heed the safety signs on the generator. wiring to power appliances, have a qualified Clean or replace all safety signs if they can- electrician install appropriate equipment.

  • Page 14: Battery Safety

    BATTERY SAFETY 4. Do not allow children to play on or around the Caution: Poison / Danger - Causes stored machine. Severe Burns. The battery contains 5. Place the generator on a level surface. Tilt- sulphuric acid. Avoid contact with skin, ing or laying it on its side can cause fuel or eyes or clothing.

  • Page 15: Diesel Engine Safety

    2.12 DIESEL ENGINE SAFETY BEFORE STARTING ENGINE, READ AND 14. Do noT use this engine on any forest UNDERSTAND THE OPERATING AND MAIN- covered, brush covered, or grass covered TENANCE INSTRUCTIONS THAT CAME WITH unimproved land unless a spark arrester is YOUR ENGINE.

  • Page 16: Sign-Off Form

    2.13 SIGN-OFF FORM Kodiak follows the general Safety Standards specified by the American Society of Agricultural and Biologi- cal Engineers (ASABE) and the occupational Safety and Health Administration (oSHA). Anyone who will be using and/or maintaining the generator must read and clearly understand ALL Safety, Usage and Main- tenance information presented in this manual.

  • Page 17: Safety Signs

    SAFETY SIGNS 1. Keep safety signs clean and legible at all times, 2. Replace safety signs that are missing or have become illegible. 3. Replaced parts that displayed a safety sign should also display the current sign. 4. Safety signs in Section 3 each have a part number displayed with it. Use this part number when ordering replacement parts.

  • Page 18: Safety Sign Locations

    Bien lire le manuel du propriétaire ent ouvertes. Z94227 KD5000D & KD7300D REMEMBER - If safety signs have been damaged, removed, become illegible or parts replaced without safety signs, new signs must be applied. new safety signs are available from your authorized dealer.

  • Page 19: Operation & Features

    Prolonged exposure can lead to unconsciousness and death. TO THE NEW OPERATOR OR OWNER The Kodiak Portable Generators are designed to provide maximum field efficiency. By following provide portable electrical power to equipment the using instructions in conjunction with a good that is not connected to the electrical grid system.

  • Page 20: Install Battery

    4.1.2 INSTALL BATTERY: 6. Install the hold down strap onto the "J" 1. Remove cables, clamps and brackets hooks over the battery. from their shipping position. 7. Tread on the wing nuts, snug up tightly. 2. Bring a battery to the machine. 8.

  • Page 21: Machine Components

    Component location for the KD7300D Fuel Shut off Control Panel Fuel Tank 6.8kVa Alternator Ignition Switch 250 CCA Battery (not Included) Kobuta oC95 For a detailed parts breakdown, see your dealer or visit the Kodiak website to download the KD Parts Manual.

  • Page 22: Machine Break-In

    MACHINE BREAK-IN PREOPERATION CHECKLIST Although there are no operational restrictions on Efficient and safe operation of the Kodiak Portable the portable generator when used for the first Generator requires that each operator reads and time, it is recommended that the following me- understands the use procedures and all related safety precautions outlined in this section.

  • Page 23: Controls

    The Low oil Shutdown system is designed to prevent engine damage caused by an insuf- ficient amount of oil in the crankcase. Before Kohler Ignition Switch KD5000D the oil level in the crankcase can fall below a safe limit, the system will automatically stop the engine...

  • Page 24: Electrical Controls

    F. Main Switch (30 Amp breaker KD7300D & 20 provide 120 Volt, 20 Amp power. amp KD5000D) is the master overload for the generator. Move the switch up to engage the B. This outlet (L5-30) is used to provide 120 Volt, breaker and down to disengage the breaker.

  • Page 25: Power Monitor

    4.5.4 POWER MONITOR Wet Stacking Kodiak Diesel Generators are designed to operate at moderate to maximum load. operating in underload condition will create an effect called "wet Stacking" Like all internal combustion engines, to operate at maximum efficiency a diesel engine has to have exactly the right air-to-fuel ratio and be able to sustain its operational temperature for a complete burn of fuel.

  • Page 26: Electrical Load

    A resistive load is lighting, hot plate, TV, etc, 4.6.1 BALANCING LOADS Resistive loads generally will not spike and start- when operating your Kodiak generator please be ing wattage is the same as running wattage. (See aware of load balancing when using 120v recep- wattage chart) tacles.

  • Page 27: Wattage Chart

    4.6.4 WATTAGE CHART The chart below contains general wattage information, and is intended to be used as a guide only. For some electrical, and electronic appliances, you can determine the power needed by looking at the data tag supplied by the manufacturer. Most products and all electrical motors should have a data tag attached to their bodies that give volts and amps and may contain wattage information.

  • Page 28: Field Operation

    FIELD OPERATION OPERATING SAFETY • Read and understand operator's manual before • Do not refuel the engine while it is in opera- starting. Review safety instructions annually. tion or still hot. Do not refuel the engine near open flames, pilot lights or sparking electrical •...

  • Page 29: Start

    4.7.2. START 1. Starting the Generator: a. Ensure the main power switch / breaker is 6. Electrical Loads: in the "off" position or turn all the appliances The generator is ideally suited to camping, or electrical loads off. boating, farm, household, workshop, con- struction site or anywhere that back-up power b.
  • Page 30 The 120/240 volt (14-30R) receptacle is 30 Amp protected by a 30 amp breaker in the (KD7300D) KD7300D and 20 amp in the KD5000D, 20 Amp which also serves as the main off/on (KD5000D) switch. If this breaker trips all the circuits will be off.

  • Page 31: Residential

    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"...

  • Page 32: Storage

    STORAGE 5.2.2 REMOVING FROM STORAGE STORAGE SAFETY when removing this machine from storage, follow • Store the unit in an area away from human this procedure: activity, or children playing • Do not store near any tool, machine, appli- 1. Remove the tarpaulin if covered. ance that produces flame or sparks.

  • Page 33: Service And Maintenance

    SERVICE AND MAINTENANCE MAINTENANCE SAFETY • Good maintenance is your responsibility. • never work under equipment unless it is Poor maintenance is an invitation to trouble. blocked securely. • Read the instructions before you begin, and • A fire extinguisher and first aid kit should make sure you have the tools and skills re- be kept readily accessible while performing quired.

  • Page 34: Maintenance

    MAINTENANCE By following a careful service and maintenance program for your machine, you will enjoy many years of trouble free operation. Ensure all operators understand how to put the machine in safe condition before working with this machine, DANGER • Flip main switch "off" or disconnect all loads •...

  • Page 35: Servicing The Battery

    6.2.4 SERVICING THE BATTERY Jump Starting Battery Read Section 2.9 on battery safety for safe Read Section 2.9 on battery safety for safe handling of the battery. handling of the battery Caution: Battery posts, w A R n I n G : terminals related frozen batteries...

  • Page 36: Specifications

    SPECIFICATIONS MECHANICAL DK Series Generators DK5000E DK7300E Specifications KD5000D KD7300D Maximum watts 5000 7300 Continuous watts 3750 6000 Maximum amps (120-V) 41.6 60.8 Continuous amps (120-V) 31.25 Maximum amps (240-V) 20.8 30.4 Continuous amps (240-V) 15.6 Full Power Feature (120V)

  • Page 37: Bolt Torque

    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...

  • Page 38: Trouble Shooting

    TROUBLE SHOOTING Kodiak generators are designed with high quality Kubota and Kohler engines combined with tested and tough 120 / 240v alternators to produce a system that very reliable and robust. In the following page, we have listed many of the causes and solutions to the problems that you may encounter.

  • Page 39: Accessories

    ACCESSORIES Call your dealer for pricing and availability #wK214 Two wHEEL KIT wITH 14'' TIRES For models: KD5000D & KD7300D A must have add on kit for true portability! #wK214 Shown mounted on KD5000D...

  • Page 40: Index

    INDEx ACCESSoRIES ..........38 MAxIMUM wATTAGE........25 AIR DISCHARGE ...........21 MAx PoSITIon ..........23 AIR InTAKE ...........21 noISE ............11 BACKFEEDInG ........13, 30 BATTERIES ...........17 oFF ..............22 BATTERY ........1, 6, 14, 34 oIL ..............32 oIL ALERT .............22 CAUTIon ............7 on ..............22 CIRCUIT BREAKERS ........29 oPERATInG HInTS ........29 CoMPonEnT ConDITIon......28...

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Kd7300d

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