EMB Wallenstein HD5000E, Operator'S Manual

Page 1: ...PORTABLE GENERATOR MODEL HD5000E HD7300E OPERATOR S MANUAL ...

Page 2: ... nearest Authorized Repair Centre or distributer Only these locations are authorized to make repairs to the product or affect the replacement of defective 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 cover...

Page 3: ...dealer and the customer at the time of deliv ery 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 the Op erator s Manual content equipment care adjustments safe operation and applicable wa...

Page 4: ...e indicated Please mark the numbers in the spaces provided for easy reference SERIAL NUMBER LOCATION Model Number _ ____________________________________________________ Generator Serial Number ____________________________________________ Machine Serial Number _____________________________________________ Generator Machine NOTE The information in this manual applies to both the HD5000E and HD7300E ...

Page 5: ... 7 2 10 Battery Safety 7 2 11 Diesel Motor Safety 8 2 12 Employee Sign Off Form 9 3 Safety Sign Locations 10 4 Assembling 12 5 Operation 14 5 1 To the New Operator or Owner 14 5 2 Machine Components 15 5 3 Machine Break In 16 5 4 Pre Operation Checklist 16 5 5 Controls 17 5 6 Field Operation 19 5 7 Moving 24 5 8 Storage 25 6 Service and Maintenance 26 6 1 Service 26 6 2 Maintenance 30 7 Troublesho...

Page 6: ...ing the generator read and understand the Safety Operation Maintenance and Trouble Shooting information contained within the Operator s Manual This manual covers the Wallenstein Portable Generator Model HD5000E 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 Wallenstein de...

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 pa...

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: ...n 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 th...

Page 11: ...erly 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 l...

Page 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 ground 14 Do not cover the generator while in operation Overheating can result in damaged equip ment 15 For storage do not cover the generator until it has cooled down completely 16 The ambient temperature should not exceed 10...

Page 13: ...ngine 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 DONOToperateenginewithoutamuffler 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 accumulat...

Page 14: ...yone 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...

Page 15: ...ctors and shields before starting and operating Do not connect the generator to a commercial power line Do 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 expo...

Page 16: ...vailable from 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 A B ...

Page 17: ...ifting moving and assembling the machine When the machine is shipped follow this procedure 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 lid 4 Use 2 men or a hoist to lift the unit out of its box Fig 1 TYPICAL ...

Page 18: ... b Bring a battery to the machine c Lay out components d Position battery in its tray e Install the anchor posts and top brackets Snug up tightly f Attach cables to battery posts and tighten to their specified torque Fig 2 BATTERY Typical Shipping Battery Clamp Arms Posts Bracket Cables ...

Page 19: ...tructions 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 starting and operating ...

Page 20: ... COMPONENTS A Engine B Fuel Tank C Battery D Control Panel E Ignition Key F 120 V Outlets G 240 V Outlets H Circuit Breakers J Generator K Pull Start L Master Breaker The unit is designed to provide electrical 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 ...

Page 21: ...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 22: ...ockwise on detent to the run position This is the position where the engine will continue to run START Turn fully clockwise to the last spring loaded detent position to engage the starter solenoid and start the engine Release the key when the engine starts and it will return to the RUN position b Starting Rope Pull sharply on the T bar when starting the engine Release the T bar when engine is runn...

Page 23: ... are used to reset the circuit breakers to the adjacent 120 Volt outlets Push the switch to reset the breaker if it is tripped d 120 Volt 30 Amp Outlet This outlet is used to provide 120 volt 30 amp power to the customer e Master Breaker This two position switch controls the master breaker for the gen erator Move the switch up to engage the breakerbeforestartingorwhenthebreaker trips and down to d...

Page 24: ...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 25: ... on 5 Stopping a Turn the appliance off 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 operating conditions but it should always be positioned on the level When t...

Page 26: ...n If the power draw for the appliance exceeds the outlet capacity the circuit breaker will be tripped Reduce the current draw and reset the breaker before re suming 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 tha...

Page 27: ...e 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 ...

Page 28: ...re fuelling 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 tem perature exceeds 100 F 39 C to preve...

Page 29: ...A frame forklift crane or other lift ing system It can also be used to lift carry manually 2 Wheel Kit A wheel kit is available to move the gen erator Place the frame into the wheel kit and move to the new location 3 Transporting When transporting from location to loca tion follow this procedure a Run the engine use the generator until the fuel tank is empty or nearly empty b Turn the fuel valve o...

Page 30: ... valve off 5 Touchupallpaintnicksandscratchestoprevent rusting 6 Remove ignition key and store in a secure place 7 Remove the battery and store it in a cool dry area on wooden blocks or a wooden pallet Charge it monthly to maintain an adequate charge 8 It is best to store the machine inside If that is not possible cover with a waterproof tarpaulin and tie down securely 9 Store in an area away from...

Page 31: ... secured to ensure unit is in a safe condition When completing a maintenance or service 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 perform ance Also acceptable is an SAE multipur pose lithium base g...

Page 32: ...sual condi tions may require more frequent lubrication or oil changes 8 Hours or Daily 1 Check engine oil level 2 Check fuel level 40 Hours or Weekly 1 Clean engine air cleaner 100 Hours or Monthly 1 Change engine oil a Drain plug b Fill plug Fig 14 ENGINE 1 2 Fig 15 AIR CLEANER Fig 16 DRAIN FILL PLUGS a b ...

Page 33: ...28 100 Hours or Monthly 3 Replace fuel filter 4 Replace engine air cleaner Annually 1 Clean machine Fig 16 INLINE FUEL FILTER Fig 17 AIR CLEANER Typical Fig 18 MACHINE ...

Page 34: ...ice 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 Fuel Filter R Air Cleaner Annually CL Machine ...

Page 35: ...NER 1 Review 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 ...

Page 36: ... oil while the engine is warm to keep the contaminants in suspension 4 Place a pan under the drain 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 Fill the crankcase with the specified oil 9 Run the engine for 1 2 minutes and check for oil leaks 10 If leaks are found around the drain pl...

Page 37: ... the area of bystanders especially small children 2 Stop engine remove ignition key and wait for all moving parts to stop before servicing or maintaining the machine 3 Turn fuel valve off between tank and filter 4 Remove filter 5 Install replacement filter 6 Wipe away any spilled fuel 7 Open fuel valve Fig 21 FUEL FILTER DANGER Do not smoke when working on fuel system Keep all sparks flames or hot...

Page 38: ...ed to generate up to 4 500 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...

Page 39: ... Hatz 1B30 Hatz 1B40 Horsepower 6 8 9 9 Maximum Watts 4400 6500 Continuous Watts 4000 5800 Frequency 60Hz 60Hz Voltage 120 240 120 240 Fuel Tank Capacity 20 L 5 2 US Gal 20 L 5 2 US Gal Engine Starting Electric and Recoil Electric Recoil Overload Protection Yes Yes Run Time Half Load approx 22 Hrs approx 22 hrs ...

Page 40: ... 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 41: ... Signs 5 Safety Training 5 Sign Off Form 9 Storage Safety 7 Safety Sign Locations 10 Service and Maintenance 26 Maintenance 30 Service 26 Specifications 34 Bolt Torque 35 T Trouble Shooting 33 A Assembly 12 I Index 36 Introduction 1 O Operation 14 Controls 17 Field Operation 19 Machine Break In 16 Machine Components 15 Pre Operation Checklist 16 Moving 24 Storage 25 To the New Operator or Owner 14...

Page 42: ...WALLENSTEIN 4144 BOOMER LINE ST CLEMENTS ON N0B 2M0 CANADA PH 519 699 9283 FAX 519 699 4146 PRINTED IN CANADA FEBRUARY 2009 PART NUMBER Z97038 ...