Surge master SM12000LHAE User manual







 



 









BY EMB MFG INC.











 

 

2.2 EQUIPMENTSAFETYGUIDELINES..........................................................9

2.3 SAFETYTRAINING...................................................................................10

2.5 PREPARATION..........................................................................................11

2.6 MAINTENANCESAFETY..........................................................................11

2.7 OPERATINGSAFETY...............................................................................12

2.8 REFUELINGSAFETY...............................................................................12

2.9 STORAGESAFETY...................................................................................12

2.10 BATTERYSAFETY....................................................................................12

2.11 GASMOTORSAFETY..............................................................................13

2.12 SIGN-OFFFORM......................................................................................14

 

 

4.1 INSTALLBATTERY:...................................................................................17

 

5.1 TOTHENEWOPERATOROROWNER..................................................18

5.2 MACHINECOMPONENTS........................................................................19

5.3 MACHINEBREAK-IN................................................................................20

5.4 PRE-OPERATIONCHECKLIST................................................................20

5.5 CONTROLS...............................................................................................21

5.51 ENGINE:....................................................................................................21

5.52 ELECTRICALCONTROLS:SM11000LHE.................................................22

5.6 FIELDOPERATION...................................................................................23

5.7 MOVING....................................................................................................28

5.8 STORAGE.................................................................................................29

5.8.1 PLACINGINSTORAGE............................................................................29

5.8.2 REMOVINGFROMSTORAGE.................................................................29

 

6.1 SERVICE...................................................................................................30

6.1.1 FLUIDSANDLUBRICANTS......................................................................30

6.1.2 FLUIDSANDLUBRICANTS......................................................................30

6.1.3 SERVICERECORD...................................................................................31

6.2 MAINTENANCE.........................................................................................31

 

 

8.1 MECHANICAL............................................................................................33

8.2 BOLTTORQUE..........................................................................................34







WARRANTY

Effective on products retailed on or after September 1, 2011.

This product is warranted to be free of defects in materials and workmanship under normal use and service, for a period of

from the date of purchase, when operated and maintained in accordance with the Operating and Maintenance Instructions

supplied with this unit. Warranty is limited to the repair of the product and/or replacement of parts.

This warranty does not cover the following items:

1) Parts lost or damaged during shipment,

2) Normal maintenance or adjustments

3) Normal replacement of service items.

4) Accessory items / parts not supplied by EMB MFG INC.

5) Damages resulting from:

• misuse, negligence, accident, theft or re

• use of improper or insufcient fuel, uids or lubricants

• use of parts or after market accessories other than genuine EMB MFG INC. parts

• modications, alteration, tampering or improper repair performed by parties other than an authorized servicer

• any device or accessories installed by parties other than an authorized EMB servicer

Engines are covered by the manufacturer of the engine and covered by the warranty period specied by that manufacturer.

Engine warranty must be registered at the engine manufactures website. For service contact your local engine dealer.

Under no circumstances will the manufacturer be liable for any consequential damage or expense of any kind, including loss

of prots. The manufacturer is under no circumstances liable for tow vehicle of any kind. The manufacturer is not liable for

the maintenance of the product.

This warranty is extended only to the original purchaser and is not transferable. Warranty is void if repairs are attempted by

anyone other than an authorized service centre.

If a difculty develops with the product, contact EMB MFG INC. Only our authorized service centres may 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 shall be returned at the customer’s expense to the authorized service centre. Damage

in transit is not covered by warranty. Include the original purchase receipt with any claim (keep a copy of the receipt

for your les).

The distributor’s liability under warranty is limited to the repair of the product and/or replacement of parts and is given to the

purchaser in lieu of all other remedies including incidental and consequential charges. There are no warranties, expressed

or implied, other than those specied herein.

EMB MFG Inc

4144 Boomer Line, St Clements, ON N0B 2M0 Canada

Phone: 519-699-9283 Fax: 519-699-4146 : attention to Warranty Dept

Email: [email protected]

WARRANTY IS VOID IF NOT REGISTERED

Three (3) Years for Consumer

One (1) Year for Commercial/Rental

rev.091111

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____ AllDecalsInstalled

____ GuardsandShieldsInstalledandSecured

____ ReviewOperatingandSafetyInstructions

____ FastenersTight

____ CheckElectricalConnections

____ CheckEngineFluidLevels







DateDealer’sRep.Signature

DateOwner'sSignature

TheaboveequipmentandOperator’sManualhavebeenreceivedbymeandIhavebeenthoroughly

instructedastocare,adjustments,safeoperationandapplicablewarrantypolicy.

Thisformmustbelled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the

Operator’sManualcontent,equipmentcare,adjustments,safeoperationandapplicablewarrantypolicy.















AlwaysgiveyourdealertheserialnumberofyourSurgeMasterPortableGeneratorwhenorderingparts

orrequestingserviceorotherinformation.

Theserialnumberplateislocatedwhereindicated.Pleasemarkthenumbersinthespacesprovidedfor

easyreference.







 











 

CongratulationsonyourchoiceofanSurgeMasterPortableGeneratortocomplimentyouroperation.

Thisequipmenthasbeendesignedandmanufacturedtomeettheneedsofadiscerningperson,operator

orindustrythatneedsportableelectricalpower.

Safe,efcientandtroublefreeoperationofyourSurgeMasterPortableGeneratorrequiresthatyouand

anyoneelsewhowillbeusingormaintainingthegenerator,readandunderstandtheSafety,Operation,

MaintenanceandTroubleShootinginformationcontainedwithintheOperator'sManual.

ThismanualcoverstheSurgeMasterPortableGeneratorModelsSM11000LHE.UsetheTableofCon-

tents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

SurgeMasterdealerortheDistributerifyouneedassistance,informationoradditionalcopiesofthe

manuals.

-Thedirectionsleft,right,frontandrear,asmentionedthroughoutthis

manual,aredeterminedwhenstandingandlookingattheelectricalpanel.





 



WhyisSAFETYimportanttoyou?

TheSafetyAlertsymbolidenties

importantsafetymessagesonthe

SurgeMasterPortableGeneratorand

inthemanual.Whenyouseethis

symbol,bealerttothepossibilityof

personalinjuryordeath.Followthe

instructionsinthesafetymessage.

ThisSafetyAlertsymbolmeans





 

 

 



Ifyouhaveanyquestionsnotansweredinthismanualorrequireadditionalcopiesorthemanualis

damaged,pleasecontactyourdealerorSurgeMaster,4144BoomerLine,St.Clements,ON,N0B2M0.

Phone(519)699-9283orFax(519)699-4146.

 - 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.

- Indicatesapotentiallyhazardous

situationthat,ifnotavoided,could

resultindeathorseriousinjury,and

includeshazardsthatareexposed

whenguardsareremoved.Itmay

alsobeusedtoalertagainstunsafe

practices.

 - Indicatesapotentiallyhazardous

situationthat,ifnotavoided,may

resultinminorormoderateinjury.It

mayalsobeusedtoalertagainst

unsafepractices.



Notetheuseofthesignalwords

andwiththesafety

messages.Theappropriatesignalwordfor

eachmessagehasbeenselectedusingthe

followingguide-lines:



 

1. ReadandunderstandtheOp-

erator’sManualandallsafety

signsbeforeusing,maintain-

ing,adjustingorcleaningthe

PortableGenerator.

2. Have a rst-aid kit available

foruseshouldtheneedarise

andknowhowtouseit.

3. Haveareextinguisheravailablefor

useshouldtheneedariseandknow

howtouseit.

4. Wear appropriate

protectivegear.This

listincludesbutisnot

limitedto:

- Ahardhat

- Protective

 shoeswithslip

 resistantrubber

 soles

- Protectiveglasses,

 gogglesorfaceshield

- Heavygloves

- HearingProtection

5. Installandsecureallguardsbeforestarting.

6. Wear suitable ear protection

for prolonged exposure to

excessivenoise.

7. Stopanddisableengine,removeignition key

andplaceinyourpocketandwaitforallmoving

parts to stop before servicing, adjusting or

repairing.

8. Clear the area of people, especially small

children,beforeusingtheunit.

9. Review safety related items annually with all

personnelwhowilloperatingormaintainingthe

PortableGenerator.



areresponsiblefortheSAFEoperation

andmaintenanceofyourSurgeMasterPort-

ableGenerator.mustensurethatyouand

anyoneelsewhoisgoingtouse,maintainorwork

aroundthePortableGeneratorbefamiliarwiththe

usingandmaintenanceproceduresandrelated

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Generator.

Remember,arethekeytosafety.Good

safetypracticesnotonlyprotectyoubutalsothe

peoplearoundyou.Makethesepracticesawork-

ingpartofyoursafetyprogram.Becertainthat

usingthisequipmentisfamiliarwith

therecommendedusingandmaintenanceproce-

duresandfollowsallthesafetyprecautions.Most

accidentscanbeprevented.Donotriskinjuryor

deathbyignoringgoodsafetypractices.

• PortableGeneratorownersmustgiveoperat-

inginstructionstooperatorsoremployees

beforeallowingthemtooperatethemachine,

andatleastannuallythereafter.

• Themostimportantsafetydeviceonthis

equipmentisaSAFEoperator.Itistheop-

erator’sresponsibilitytoreadandunderstand

ALLSafetyandOperatinginstructionsinthe

manualandtofollowthese.Mostaccidents

canbeavoided.

• Apersonwhohasnotreadandunderstoodall

usingandsafetyinstructionsisnotqualied

tousethemachine.Anuntrainedoperator

exposeshimselfandbystanderstopossible

seriousinjuryordeath.

• Donotmodifytheequipmentinanyway.

Unauthorizedmodicationmayimpairthe

functionand/orsafetyandcouldaffectthelife

oftheequipment.

• ThinkSAFETY!WorkSAFELY!



 

1.Safetyoftheoperatorandbystandersisone

ofthemainconcernsindesigningandde-

velopingequipment.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accidents

byobservingthefollowingprecautionsinthis

section.Toavoidpersonalinjuryordeath,

studythefollowingprecautionsandinsist

thoseworkingwithyou,orforyou,follow

them.

2. Inordertoprovideabetterview,certain

photographsorillustrationsinthismanual

mayshowanassemblywithasafetyshield

removed.However,equipmentshouldnever

beusedinthiscondition.Keepallshieldsin

place.Ifshieldremovalbecomesnecessary

forrepairs,replacetheshieldpriortouse.

3. Replaceanysafetysignorinstructionsign

thatisnotreadableorismissing.Locationof

suchsafetysignsisindicatedinthismanual.

4. Neverusealcoholicbeveragesordrugswhich

canhinderalertnessorcoordinationwhileus-

ingthisequipment.Consultyourdoctorabout

usingthismachinewhiletakingprescription

medications.

5. 











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andphysicallyablepersonfamiliar

withmachineryandtrainedinthisequipment's

operations.Iftheelderlyareassistingwith

work,theirphysicallimitationsneedtobe

recognizedandaccommodated.

7. Neverexceedthelimitsofapieceofmachin-

ery.Ifitsabilitytodoajob,ortodososafely,

isinquestion-

8.Donotmodifytheequipmentinanyway.Un-

authorizedmodicationmayresultinserious

injuryordeathandmayimpairthefunction

andlifeoftheequipment.

9.Inadditiontothedesignandcongurationof

thisimplement,includingSafetySignsand

SafetyEquipment,hazardcontrolandac-

cidentpreventionaredependentuponthe

awareness,concern,prudence,andproper

trainingofpersonnelinvolvedintheoperation,

transport,maintenance,andstorageofthe

machine.ReferalsotoSafetyMessagesand

operationinstructionineachoftheappropri-

atesectionsoftheengineandmachinemanu-

als.PaycloseattentiontotheSafetySigns

afxedtotheengineandthemachine.



 

1.Safetyisaprimaryconcerninthedesignand

manufactureofourproducts.Unfortunately,

oureffortstoprovidesafeequipmentcan

bewipedoutbyasinglecarelessactofan

operatororbystander.

2. Inadditiontothedesignandcongurationof

equipment,hazardcontrolandaccidentpre-

ventionaredependentupontheawareness,

concern,prudenceandpropertrainingof

personnelinvolvedintheoperation,transport,

maintenanceandstorageofthisequipment.

3. Ithasbeensaid,"The

bestsafetyfeatureisan

informed,carefulopera-

tor."Weaskyoutobethat

kindofanoperator.Itisthe

operator'sresponsibilitytoreadandunder-

standALLSafetyandUsinginstructionsinthe

manualandtofollowthese.Accidentscanbe

avoided.

4. 















 





 

5.Knowyourcontrolsandhowtostopengine

andmachinequicklyinanemergency.Read

thismanualandtheoneprovidedwithyour

engine.

6. Train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qualiedtouse

themachine.Anuntrainedoperatorexposes

himselfandbystanderstopossibleseriousin-

juryordeath.Iftheelderlyareassistingwith

thework,theirphysicallimitationsneedtobe

recognizedandaccommodated.

 

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displayedinSection3eachhave

apartnumberinthelowerrighthandcorner.

Usethispartnumberwhenorderingreplace-

mentparts.

5. Safetysignsareavailablefromyourauthor-

izedDistributororDealerPartsDepartmentor

thefactory.



• Besurethattheinstallationareaiscleanand

dry.

• Besuretemperatureisabove50°F(10°C).

• Determineexactpositionbeforeyouremove

thebackingpaper.

• Removethesmallestportionofthesplitback-

ingpaper.

• Alignthesignoverthespeciedareaand

carefullypressthesmallportionwiththeex-

posedstickybackinginplace.

• Slowlypeelbacktheremainingpaperand

carefullysmooththeremainingportionofthe

signinplace.

• Smallairpocketscanbepiercedwithapin

andsmoothedoutusingthepieceofsign

backingpaper.



 

1.Neverusetheengineandmachineuntilyou

havereadandcompletelyunderstandthis

manual,theEngineOperator'sManualand

eachoftheSafetyMessagesfoundonthe

safetysignsontheengineandmachine.

2. Personalpro-

tectionequip-

mentincluding

hardhat,safety

glasses,safety

shoes,and

glovesarerec-

ommendeddur-

ingassembly,

installation,operation,adjustment,maintain-

ing,repairing,removal,cleaning,ormoving

theunit.Donotallowlonghair,loosetting

clothingorjewellerytobearoundequipment.

3. 







 Powerequipmentwithor

withoutequipmentattached

canoftenbenoisyenough

tocausepermanent,partial

hearingloss.Werecommendthatyouwear

hearingprotectiononafull-timebasisifthe

noiseintheOperator'spositionexceeds80db.

Noiseover85dbonalong-termbasiscan

causeseverehearingloss.Noiseover90db

adjacenttotheOperatoroveralong-termba-

sismaycausepermanent,totalhearingloss.

Hearinglossfromloudnoise(from

tractors,chainsaws,radios,andothersuch

sourcesclosetotheear)iscumulativeovera

lifetimewithouthopeofnaturalrecovery.

4. Clearworkingareaofstones,branchesor

hiddenobstaclesthatmightbehookedor

snagged,causinginjuryordamage.

5. Useonlyindaylightorgoodarticiallight.

6. Besuremachineisproperly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.

 

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

 lightforthejobat

 hand.

3. Makesurethereis

plentyofventilation.Neveroperatetheen-

gineofthetowingvehicleinaclosedbuilding.

Theexhaustfumesmaycauseasphyxiation.

4. Beforeworkingonthismachine,shutoffthe

engineandturnfuelvalveoff.

5. Neverworkunderequipmentunlessitis

blockedsecurely.

6. Alwaysusepersonalprotectiondevicessuch

aseye,handandhearingprotectors,when

performinganyserviceormaintenancework.

7. Wherereplacementpartsarenecessaryfor

periodicmaintenanceandservicing,genuine

factoryreplacementpartsmustbeusedto

restoreyourequipmenttooriginalspecica-

tions.Themanufacturerwillnotberesponsi-

bleforinjuriesordamagescausedbyuseof

unapprovedpartsand/oraccessories.

8. Areextinguisherandrstaidkitshouldbe

keptreadily

accessiblewhile

performingmain-

tenanceonthis

equipment.

9. Periodicallytightenallbolts,

nutsandscrewsandcheckthatallelectrical

andfuelconnectionsareproperlysecuredto

ensureunitisinasafecondition.

10. Whencompletingamaintenanceorservice

function,makesureallsafetyshieldsand

devicesareinstalledbeforeplacingunitin

service.



 

1. Readandunderstandoperator'smanualbefore

starting.Reviewsafetyinstructionsannually.

2. 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.

3. 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.

4. Close and secure all guards, deectors and

shieldsbeforestartingandoperating.

5. Donotconnectthegeneratortoacommercial

powerline.

8. Do not operate with damaged or defective

extensioncords,orpowercords.Neveroper-

ateanyelectricalequipmentwithdamagedor

defectivecords.

9. 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.

10. Donotrefueltheenginewhileitisinoperation

orstillhot.Donotrefueltheenginenearopen

ames,pilotlightsorsparkingelectricaldevices

(e.g.powertools,weldersorgrinders).Donot

operatethegeneratornearammable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

ground.

14. Donotcoverthegeneratorwhileinoperation.

Overheatingcanresultindamagedequipment.

15. Forstorage,donotcoverthegeneratoruntilit

hascooleddowncompletely.

16. The ambient temperature should not exceed

100°F/40°C.

 

1. Handlefuelwithcare.Itishighlyammable.

2. Allowenginetocoolfor5minutesbeforerefu-

elling.Cleanupspilledfuelbeforerestarting

engine.

3. Donotrefuelthemachine

whilesmokingorwhen

nearopenameorsparks.

4. Fillfueltankoutdoors.

5. Preventresbykeepingmachinecleanofac-

cumulatedtrash,greaseanddebris.

 

1. Storetheunitinanareaawayfromhuman

activity.

2. Donotallowchildrentoplayonoraroundthe

storedmachine.

3. Storetheunitinadry,levelarea.Supportthe

framewithplanksifrequired.

 

1. Keepallsparksandamesawayfrombatter-

ies,asgasgivenoffbyelectrolyteisexplo-

sive.

2. Avoidcontactwithbatteryelectrolyte:wash

offanspilledelectrolyteimmediately.

3. Wearsafetyglasseswhenworkingnearbat-

teries.

4. Donottipbatteriesmorethan45°,toavoid

electrolyteloss.

5. Toavoidinjuryfromsparkorshortcircuit,dis-

connectbatterygroundcablebeforeservicing

anypartoftheelectricalsystem.



 











1. DONOTrunengineinanenclosedarea.Ex-

haustgasescontaincarbonmonoxide,anodour-

lessanddeadlypoison.

2. DO NOT place hands or feet near moving or

rotatingparts.

3. DO NOT store, spill, or use gasoline near an

opename,ordevicessuchasastove,furnace,

orwaterheaterwhichuseapilotlightordevices

whichcancreateaspark.

4. DONOTrefuel indoorswhereareaisnotwell

ventilated.Outdoorrefuellingispreferred.

5. DONOTrefuelwhileengineisrunning.Allow

engine to cool for 5 minutes before refuelling.

Storefuelinapprovedsafetycontainers.

6. DONOTremovefueltankcapwhileengineis

running.

7. DO NOT operate engine if gasoline is spilled.

Movemachineawayfromthespillandavoidcre-

atinganyignitionuntilgasolinehasevaporated.

8. DONOTsmokewhilellingfueltank.

9. DONOTchokecarburetortostopengine.When-

ever possible, gradually reduce engine speed

beforestopping.

10. DONOTrunengineaboveratedspeeds.This

mayresultininjury.

11. DONOTtamperwithgovernorsprings,gover-

norlinksorotherpartswhichmayincreasethe

governedspeed.

12. DONOTtamperwiththeenginespeedselected

bytheoriginalequipmentmanufacturer.

13. DONOTcheckforsparkwithsparkplugorspark

plugwireremoved.

14. DONOTcrankenginewithsparkplugremoved.

Ifengineisooded,crankuntilenginestarts.

15. DO NOT strike ywheel with a hard object or

metaltoolasthismaycauseywheeltoshatter

inoperation.Usepropertoolstoserviceengine.

16. DONOToperateenginewithoutamufer.Inspect

periodicallyandreplace,ifnecessary.Ifengine

isequippedwithamuferdeector,inspectpe-

riodicallyand replace, ifnecessary withcorrect

deector.

17. DONOToperateenginewithanaccumulationof

grass,leaves,dirtorothercombustiblematerials

inthemuferarea.

18. DONOTusethisengineonanyforestcovered,

brushcovered,orgrasscoveredunimprovedland

unlessasparkarresterisinstalledonthemufer.

Thearrestermustbemaintainedineffectivework-

ingorderbytheoperator.InthestateofCalifornia

theaboveisrequiredbylaw(Section4442ofthe

CaliforniaPublicResourcesCode).Otherstates

may have similar laws.  Federal laws apply on

federalland.

19. DO NOT touch hot mufer, cylinder or ns be-

causecontactmaycauseburns.

20. DONOTrunenginewithaircleaneroraircleaner

coverremoved.



1. ALWAYSDOremovethewirefromthesparkplug

whenservicingtheengineorequipmenttopre-

ventaccidentalstarting.Disconnectthenegative

wirefromthebatteryterminalifequippedwita12

voltstartingsystem.

2. DOkeepcylindernsandgovernorpartsfreeof

grassand other debris whichcanaffectengine

speed.

3. DOexaminemuferperiodicallytobesureitis

functioningeffectively.Awornorleakingmufer

shouldberepairedorreplacedasnecessary.

4. DOusefreshgasoline.Stalefuelcangumcar-

buretorandcauseleakage.

5. DO check fuel lines and ttings frequently for

cracksorleaks.Replaceifnecessary.



 

SurgeMasterfollowsthegeneralSafetyStandardsspeciedbytheAmericanSocietyofAgriculturaland

BiologicalEngineers(ASABE)andtheOccupationalSafetyandHealthAdministration(OSHA).Anyonewho

willbeusingand/ormaintainingthePortableGeneratormustreadandclearlyunderstandALLSafety,Usage

andMaintenanceinformationpresentedinthismanual.

Donotuseorallowanyone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unqualiedtousethismachine.

Asign-offsheetisprovidedforyourrecordkeepingtoshowthatallpersonnelwhowillbeworkingwiththe

equipmenthavereadandunderstandtheinformationintheOperator’sManualandhavebeeninstructedin

theoperationoftheequipment.

 







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.

 

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!



 





 





 





        



 

        

        



 

        





 









 



 



 



 



 



 





Z94216





























 

Themachinecomesfromthefactoryinashipping

crateandconguration.Alwaysusetoolsequipment

andforkliftsofappropriatesizeandcapacityforthe

job. Always use 2 men when lifting, 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sufcientclearancetoaccessthe

machinefromallsides.

3. Removethelidandlaytotheside.

4. Useahoistoracranetolifttheunitoutofits

crate.





 

1. Removecables,clampsandbrackets

fromtheirshippingposition.

2. Bringabatterytothemachine.

3. Layoutcomponents.

4. Positionbatteryinitstray.

5. Installthethreaded"J"hooksintothebat-

terytray.

36Ahbatteryisrecommended

6. Installtheholddownstrapontothe"J"

hooksoverthebattery.

7. Treadonthewingnuts,snuguptightly.

8. Attachcablefromthestartersolonoid

topositive(+)batterypostandtighten

sucurely.

9. Attachthecablefromthegroundposton

thestartertothenegative(-)postonthe

battery(neutralisbondedtotheframe)

Poison/Danger-Causes

SevereBurns.Thebatterycontains

sulphuric acid.Avoid contact with skin,

eyes or clothing. Keep out of reach of

children.

BATTERYSAFETY

1. Wearglovesandsafetyglassesorfaceshield

whenworkingonornearbatteries.

2. Useabatterycarriertoliftthebatteryorplace

handsatoppositecornerstoavoidspilling

acidthroughthevents.

3. Avoidcontactwithbatteryelectrolyte:

Flushimmediatelywith

water.    

Flushwithwaterfor15minutes.

Getpromptmedicalattention.Cleanupany

spilledelectrolyteimmediately.

4. Avoidcontactwithbatteryposts,terminals

andrelatedaccessories,theycontainlead

andleadcompounds,chemicalsknownto

causeharm.Washhandsimmediatelyafter

handlingbattery.

5. Keepallsparksandamesawayfrombatter-

ies,asgasgivenoffbyelectrolyteisexplo-

sive.

6. Toavoidinjuryfromsparkorshortcircuit,dis-

connectbatterygroundcablebeforeservicing

anypartoftheelectricalsystem.

7. FROZENBATTERIESCANEXPLODEand

resultindeathorseriousinjury.DONOTjump

start/chargeafrozenbattery.Letbattery

thawbeforecharging.

StarterGround

Post(-)

StarterSolenoid(+)

WingNut

HoldDownStrap

BatteryCable

"J"Hook



 

TheSurgeMasterPortableGeneratorsarede-

signedtoprovideportableelectricalpowerto

equipmentthatisnotconnectedtotheelectrical

gridsystem.





















Manyfeaturesincorporatedintothismachineare

theresultofsuggestionsmadebycustomerslike

you.Readthismanualcarefullytolearnhow

tousetheGeneratorsafelyandhowtosetitto

providemaximumeldefciency.Byfollowing

theusinginstructionsinconjunctionwithagood

maintenanceprogram,yourPortableGenerator

willprovidemanyyearsoftrouble-freeservice.

 



• Readandunderstandoperator'smanualbefore

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, deectors 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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operation

orstillhot.Donotrefueltheenginenearopen

ames,pilotlightsorsparkingelectricaldevices

(e.g.powertools,weldersorgrinders).Donot

operatethegeneratornearammableproducts.

• Theengineshouldberefuelledinawell-litarea.

Avoidfuelspillage.

• Neverallowchildren or unauthorizedpeople

tooperateorbearoundthismachine.

• Keeptheworkingareacleanandfreeofde-

bristopreventtripping.Operateonlyonlevel

ground.

• Donotcoverthegeneratorwhileinoperation.

Overheatingcanresultindamagedequipment.

• Forstorage,donotcoverthegeneratoruntilit

hascooleddowncompletely.

• Theambienttemperatureshouldnotexceed

100°F/40°C.



 

The SurgeMaster SM11000LHE Port-

able Generator consists of a 20 hp Hon-

da engine driving a 11,000 watt electrical

generator.  All control and power out-

lets are mounted on the front of the frame for

convenientaccessandoperation.

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bondedto

theframe.Thebatteryandfueltankaremountedin

theframeforconvenientaccess.

HOURS 1/10

HondaGX630

Engine 12kVa

Alternator

Electrical

Control

Panel

Battery

(notincluded,

36Ahrecommended)

FuelTank

LiftEye

20AmpBreakers

120/240vOutlets

120vOutlets

MainSwitch

HourMeter

OilAlert

Choke

HondaGX630

ControlPanel

Ignition

Note:checktheHonda

GX630ownersmanualfor

detailedengineinformation.

FuelShut-off

RearView

30AmpBreakers



 

Althoughtherearenooperationalrestrictionsonthe

PortableGeneratorwhenusedforthersttime,itis

recommendedthatthefollowingmechanicalitems

bechecked:

A. 

 1. Re-torqueallfastenersandhardware.

 2. Check condition of all electrical connec-

tions.

 3. Checkuidlevels.Topupasrequired.

B. 

 1. Repeatsteps1through3listedabove.

  (SectionA)

 2. Changeengineoil.

 3. Go to the normal servicing and mainte-

nancescheduleasdenedintheMainte-

nanceSection.

 

Efcient and safe operation of the SurgeMaster

Portable Generator requires that each operator

readsandunderstandstheusingproceduresand

allrelatedsafety precautions outlinedinthis sec-

tion.A pre-operationchecklistisprovidedforthe

operator.Itisimportantforboththepersonalsafety

andmaintaininggoodmechanicalconditionthatthis

checklistisfollowed.

BeforeoperatingPortableGeneratorandeachtime

thereafter,thefollowingareasshouldbechecked

off:

1. Checkengineuidlevels.Topupasrequired.

2. Checkallelectricalconnections.Replace,re-

pairorcleanasrequired.

3. Make sure that all guards and shields are in

place,securedandfunctioningasdesigned.

Surge master SM12000LHAE User manual

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