Wallenstein GF5000A, Manual

Page 1: ...peration Maintenance and Trouble Shooting information contained within the Operator s Manual ThismanualcoverstheWallensteinPortableGeneratorModelsGF5000A GF5000EA GF6000A GF6000EA and GF7200EA 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 Distr...

Page 2: ...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 3: ...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 4: ...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 5: ...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 6: ...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 7: ...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 8: ...gine 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 accumulati...

Page 9: ...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 10: ...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 11: ...rom 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 GF6000A GF7200EA B A B A ...

Page 12: ...nd 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 Movethemachinetotheassemblyarea 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 UNPACKING ...

Page 13: ... Bring a battery to the machine c Lay out components d Position battery in its tray e Install the anchor posts and top brack ets Snug up tightly f Attach cables to battery posts and tighten to their specified torque Fig 3 BATTERY Typical Shipping Lay Out Battery Posts Bracket Cables 13 ...

Page 14: ...e starting 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 be...

Page 15: ... 4 PRINCIPLE COMPONENTS A Engine B Fuel Tank C Battery D Control Panel E Ignition Key F 120 V Outlets G 240 V Outlets H Circuit Breaker J Idle Relay K Generator L Master Breaker M Hour Meter The unit is designed to provide 120 V or 240 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 machine is neutral bonde...

Page 16: ...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 17: ...he choke for starting when the engine is cold Push the knob in to open the choke as the engine warms Always push the knob fully in when operating the machine d Ignition Switch Manual Start This switch controls the electrical power to the engine electrical system Turn the switch counter clockwise to turn OFF Turn clockwise to the first position for ON e Choke This lever controls the position of the...

Page 18: ...reaker This two position switch controls the master breaker for the gen erator Move the switch up to engage the breaker before starting or when the breaker trips and down to disengage the breaker f Hour Meter This meter measures and displays the time the generator has been operating g Automatic Idle Control This six position rotary switch sets the operating time of the generator before the engine ...

Page 19: ...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 20: ...the appliance 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 o...

Page 21: ...nce 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 le...

Page 22: ...the engine runs at full throttle before it slows to low idle In an application where the electrical load is intermittent skill saws drills other hand tools etc the idle control maintains the engine at full RPM and the generator at full generating capacity to allow work to con tinue without interruption Turn the rotary switch to set the length of time at high idle that works best for your applicati...

Page 23: ...ep 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 temperature exceeds 100 F 39 C to prevent overheating g ...

Page 24: ...location to attach when moving with an A frame forklift crane or by hand 2 Wheel Kit A wheel kit is available to move the generator 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 line off 5 7 MOVING Fig 12 ...

Page 25: ...ve 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 hum...

Page 26: ...ed 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 greasewithextremepressure EP performance Also acceptable is an SAE multipurpose lithium base grease 2 Eng...

Page 27: ...g 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 40 Hours or Weekly 1 Clean engine air cleaner Fig 15 MACHINE Typical a Dip Stick b Fuel Tank b a Fig 16 AIR CLEANER Typical ...

Page 28: ...28 100 Hours or Monthly 1 Change engine oil 2 Replace engine air cleaner Annually 1 Clean machine Fig 17 ENGINE Typical Fig 19 MACHINE Typical Fig 18 AIR CLEANER Typical a Drain Plug b Fill Plug a b ...

Page 29: ...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 30: ...R 1 Review the Operator s Manual for the engine 2 Place all controls in neutral stop engine and remove ignition key and place in pocket 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 debris out of the filter 6 Install filter 7 Install and secure the cover Fig 20 AIR CLEANER Typical ...

Page 31: ... 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 plug or filter tighten slightly...

Page 32: ...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 33: ...37 5 18 8 37 5 18 8 41 6 20 8 41 6 18 8 54 1 27 1 Frequency 60 Hz 60 Hz 60 Hz 60 Hz 60 Hz Voltage 120 240V 120 240V 120 240V 120 240V 120 240V Fuel Tank Capacity 21 L 5 5 gal 21 L 5 5 gal 21 L 5 5 gal 21 L 5 5 gal 21 L 5 5 gal Run Time Hrs 1 2 12 12 12 12 11 5 Full 7 7 7 7 6 5 Weight 159 lbs 163 lbs 186 lbs 189 lbs 208 lbs Dimensions L 28 28 28 28 28 W 20 20 20 20 20 H 24 24 24 24 24 Oil Alert Sys...

Page 34: ... 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 35: ...Safety Training 5 Sign Off Form 9 Storage Safety 7 Safety Sign Locations 10 Service and Maintenance 26 Maintenance 30 Service 26 Specifications 33 Bolt Torque 34 Mechanical 33 T Trouble Shooting 32 A Assembly 12 I Index 37 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 Own...