EMB Wallenstein EC2500, Operator'S Manual

Page 1: ...1 PORTABLE GENERATOR MODELS EC2500 EC2600 EC3300 EC5000 OPERATOR S MANUAL EC2500 EC2600 EC3300 EC5000 ...

Page 2: ... Authorized Repair Centre or distributer Only these locations are authorized to make repairs to the product or affect the replacement of defec tive parts which will be done at no charge within a reasonable time after the receipt of the product Unit or parts should be returned at the customer s expense to the nearest repair location or Authorized Service Centre Damage in transit is not covered by w...

Page 3: ...plicable warranty policy This form must be filled out by the dealer and signed by both the dealer and the customer at the time of delivery Customer s Name Dealer Name Address Address City State Province Code City State Province Code Phone Number Phone Number Contact Name Model Serial Number Delivery Date I have thoroughly instructed the buyer on the above described equipment which review included ...

Page 4: ...serial number plates are located where indicated Please mark the numbers in the spaces provided for easy reference SERIAL NUMBER LOCATION Model Number ___________________________________________________________ Generator Serial Number ___________________________________________________ Engine Serial Number ______________________________________________________ EC2500 EC2600 ...

Page 5: ...torage Safety 7 2 10 Gas Motor Safety 8 2 11 Employee Sign Off Form 9 3 Safety Sign Locations 10 4 Assembling 12 5 Operation 13 5 1 To the New Operator or Owner 13 5 2 Machine Components 14 5 3 Machine Break In 15 5 4 Pre Operation Checklist 15 5 5 Controls 16 5 6 Field Operation 18 5 7 Moving 23 5 8 Storage 24 6 Service and Maintenance 25 6 1 Service 25 6 2 Maintenance 30 7 Troubleshooting 32 8 S...

Page 6: ...eration Maintenance and Trouble Shooting information contained within the Operator s Manual This manual covers the Wallenstein Portable Generator Models EC2500 EC2600 EC3300 and EC5000 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 Wal lenstein dealer or the Distributer i...

Page 7: ...9 9283 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 ...

Page 8: ... the using and maintenance procedures and related SAFETY information contained in this manual This manual will take you step by step through your working day and alerts you to all good safety practices that should be used while using the Portable Genera tor Remember YOU are the key to safety Good safety practices not only protect you but also the people around you Make these practices a work ing p...

Page 9: ...llowed to work with this equipment Do not allow persons to use or assemble this unit until they have read this manual and have developed a thorough understanding of the safety precautions and of how it works Review the safety instructions with all users annually 6 This equipment is dangerous to children and persons unfamiliar with its operation The operator should be a responsible properly trained...

Page 10: ...in all new personnel and review instruc tions frequently with existing workers Be certain only a properly trained and physically able person will use the machinery A person who has not read and understood all using and safety instructions is not qualified to use the machine An untrained operator exposes himself and bystanders to possible serious in jury or death If the elderly are assisting with t...

Page 11: ...operly positioned ad justed and in good operating condition 7 Ensure that all safety shielding and safety signs are properly installed and in good condi tion 2 6 MAINTENANCE SAFETY 1 Good maintenance is your responsibility Poor maintenance is an invitation to trouble 2 Follow good shop practices Keep service area clean and dry Be sure electrical outlets and tools are properly grounded Use adequate...

Page 12: ...ar open flames pilot lights or sparking electrical devices e g power tools welders or grinders Do not operate the generator near flammable products 11 The engine should be refueled in a well lit area Avoid fuel spillage 12 Never allow children or unauthorized people to operate or be around this machine 13 Keep the working area clean and free of de bris to prevent tripping Operate only on level gro...

Page 13: ... engine starts 15 DO NOT strike flywheel with a hard object or metal tool as this may cause flywheel to shatter in operation Use proper tools to service engine 16 DO NOT operate engine without a muffler Inspect periodically and replace if necessary If engine is equipped with a muffler deflector inspect pe riodically and replace if necessary with correct deflector 17 DO NOT operate engine with an a...

Page 14: ...nyone 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 workin...

Page 15: ...o not operate with damaged or defective extension cords or power cords Never operate any electrical equipment with damaged or defective cords Do not operate this generator in areas with poor ventila tion The exhaust fumes contain carbon monoxide a poisonous odorless invisible gas Prolonged exposure can lead to unconsciousness and death Do not refuel the engine while it is in operation or still hot...

Page 16: ...om your authorized dealer The types of safety signs and locations on the equipment are shown in the illustrations that follow Good safety requires that you familiarize yourself with the various safety signs the type of warning and the area or particular function related to that area that requires your SAFETY AWARENESS Think SAFETY Work SAFELY EC2500 EC2600 A B A B C C ...

Page 17: ... and assembling the machine When the machine is shipped follow this proce dure when preparing for the customer 1 Clear the area of bystanders especially small children before starting 2 Move the machine to the assembly area Be sure there is sufficient clearance to access the machine from all sides 3 Open the carton 4 Use a hoist or a crane to lift the unit out of its carton Fig 1 TYPICAL Fig 2 UNP...

Page 18: ...arting Review safety instructions annually Stop and disable engine remove ignition key 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 It should be grounded in damp or highly conduc tive conditions Close and secure all guards deflectors and shields before...

Page 19: ...nt access and operation Fig 3 PRINCIPLE COMPONENTS A Engine B Fuel Tank C Control Panel D Ignition Switch E 120 V Outlets F Circuit Breaker G Generator The unit is designed to provide 120 V 60 Hz power as a back up power supply at a remote location Each outlet is designed with a circuit breaker to protect against overload The generator is neutral bonded to the frame The fuel tank is part of the en...

Page 20: ...e nance Section 5 4 PRE OPERATION CHECKLIST Efficient and safe operation of the Wallenstein Port able Generator requires that each operator reads and understands the using procedures and all related safety precautions outlined in this section A pre operation checklist is provided for the opera tor It is important for both the personal safety and maintaining good mechanical condition that this chec...

Page 21: ...o close the choke valve for starting when the engine is cold Slide to the right to open the choke as the engine warms Always open the choke fully when op erating the machine c Throttle This lever controls the engine RPM The engine always runs at maximum RPM when operating d Fuel Shut Off Valve This valve controls the flow of fuel to the engine Turn the valve at right an gles to the fuel line to tu...

Page 22: ...Amp Outlets These outlets are used to provide 120 volt 30 amp power to the customer d 240 Volt 20 Amp Outlets These outlets are used to provide 240 volt 20 amp power to the customer e Circuit Breakers These push switch es are used to reset the circuit breakers to the adjacent outlets Push the switch to reset the breaker if it is tripped EC2500 EC2600 IMPORTANT A circuit breaker that trips repeated...

Page 23: ...Do not operate with damaged or defective extension cords or power cords Never oper ate any electrical equipment with damaged or defective cords Do not operate this generator in areas with poor ventilation The exhaust fumes contain carbon monoxide a poisonous odorless invisible gas Prolonged exposure can lead to unconscious ness and death Do not refuel the engine while it is in opera tion or still ...

Page 24: ...pliance on or plug in the electrical load 5 Stopping a Turn the appliance off or unplug the electrical load b Run the engine for approximately three minutes to allow the engine to cool c Turn engine off 6 Emergency Stopping Turn the engine off if an emergency arises Correct the condition before resuming work and re starting the engine 7 Terrain The generator works well in a wide variety of operati...

Page 25: ...exceeds the outlet capacity the cir cuit breaker will be tripped Reduce the current draw and reset the breaker before resuming operation 10 Electrical Component Condition Always use electrical components that are in good condition Do not use electrical cords plugs and connectors that are frayed damaged cracked or not in good condition Electrical components that are not in good condition can lead t...

Page 26: ... not limited to a Keep all electrical components in good condition b Do not operate with frayed cracked or damaged parts c Ground the frame if operating in damp or wet conditions d Do not operate with wet hands 12 Circuit Breakers Each set of outlets on the electrical panel is designed with a circuit breaker to pre vent overloading the circuit If a breaker trips reduce the load before re setting t...

Page 27: ...c Keep the working area neat and clean to prevent slipping and tripping Prevent accidents at the work site d Always ground the frame to minimize the chance of sparks shocks or shorts This is very important in damp wet or rainy conditions e Position the generator under cover to protect it from rain or bad weather f Do not operate when the ambient temper ature exceeds 100 F 39 C to prevent overheati...

Page 28: ... locations for moving with an A frame forklift crane or by hand 2 Wheel Kit A wheel kit is available to move the genera tor Place the frame into the wheel kit and move to the new location 3 Transporting When transporting from location to location follow this procedure a Run the engine use the generator until the fuel tank is empty or nearly empty b Turn the fuel valve off 5 7 MOVING Fig 11 WHEEL U...

Page 29: ...ve all dirt mud or debris 3 Inspect all rotating parts for entangled material Remove all entangled material 4 Turn fuel valve off 5 Touch up all paint nicks and scratches to prevent rusting 6 It is best to store the machine inside If that is not possible cover with a waterproof tarpaulin and tie down securely 7 Store in an area away from human activity 8 Do not allow children to play around the st...

Page 30: ...ice function make sure all safety shields and de vices are installed before placing unit in serv ice 6 SERVICE AND MAINTENANCE 6 1 SERVICE 6 1 1 FLUIDS AND LUBRICANTS 1 Grease Use an SAE multipurpose high temperature grease with extreme pressure EP performance Also acceptable is an SAE multipurpose lithium base grease 2 Engine Oil Use an SAE 10W30 or 10W40 multi viscosity oil meeting the American ...

Page 31: ...mal operating conditions Severe or unusual condi tions may require more frequent lubrication or oil changes 8 Hours or Daily 1 Check engine oil level 2 Check fuel level Fig 14 ENGINE Typical EC2500 b Fuel Level EC2600 a Oil Level b Fuel Level b a b EC2500 a Oil Level a ...

Page 32: ...32 40 Hours or Weekly 1 Clean engine air cleaner 100 Hours or Monthly 1 Change engine oil Fig 15 AIR CLEANER Typical Fig 16 DRAIN PLUG Typical EC2500 EC2600 EC2500 EC2600 ...

Page 33: ...33 100 Hours or Monthly 2 Replace engine air cleaner Annually 1 Clean machine Fig 17 AIR CLEANER Typical Fig 18 MACHINE EC2500 EC2600 EC2500 EC2600 ...

Page 34: ...of service Copy this page to continue record ACTION CODE CK CHECK CL CLEAN R REPLACE CH CHANGE HOURS SERVICED BY MAINTENANCE 8 Hours or Daily CK Engine Oil Level CK Fuel Level 40 Hours or Weekly CL Air Cleaner 100 Hours or Monthly CH Engine Oil R Air Cleaner Annually CL Machine ...

Page 35: ...ew the Operator s Manual for the en gine 2 Place all controls in neutral stop engine and remove ignition key and place in pock et before maintaining 3 Remove the cover over the air cleaner 4 Remove the filter from the engine 5 Use an air house to blow the dust and de bris out of the filter 6 Install filter 7 Install and secure the cover Fig 19 AIR CLEANER Typical EC2500 EC2600 ...

Page 36: ...nge oil while the engine is warm to keep the contaminants in suspension 4 Place a pan under the drain plug a Drain plug b Fill plug 5 Remove the drain plug and allow the oil to drain for 10 minutes 6 Install and tighten the drain plug 7 Dispose of the used oil in an approved container 8 Run the engine for 1 2 minutes and check for oil leaks 9 If leaks are found around the drain plug tighten slight...

Page 37: ...000 continuous watts of power at any type of remote location It is a simple and reliable system that requires minimal maintenance In the following section we have listed many of the problems causes and solutions to the problems that you may encounter If you encounter a problem that is difficult to solve even after having read through this trouble shooting section please call your local distributor...

Page 38: ...600 2300 3300 3000 5000 4500 Max continuous amps 120 V 20 8 17 5 21 6 19 27 5 25 41 6 37 5 Volts Frequency 120 V 60 Hz 120 V 60 Hz 120 V 60 Hz 120 V 60 Hz Full tank capacity 2 litres 3 7 litres 3 7 litres 6 0 litres Run time hours Half full load 3 2 5 4 3 4 3 4 3 Weight lbs 68 74 85 122 Dimensions in L W H 22 16 16 22 16 16 22 16 16 25 5 20 21 ...

Page 39: ... 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 40: ...raining 5 Sign Off Form 9 Storage Safety 7 Safety Sign Locations 10 Service and Maintenance 25 Maintenance 30 Service 25 Specifications 33 Bolt Torque 33 Mechanical 33 T Trouble Shooting 34 A Assembly 12 I Index 35 Introduction 1 O Operation 13 Controls 16 Field Operation 18 Machine Break In 15 Machine Components 14 Pre Operation Checklist 15 Moving 23 Storage 24 To the New Operator or Owner 14 ...