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Summary of Contents for Surge master SM11000LHE
- Page 1 EMB MFG INC. EMB Manufacturing Inc. 4144 Boomer Line · St. Clements, On · N0B 2M0 · Canada Ph: (519) 699-9283 · Fax: (519) 699-4146 www.embmfg.com SM11000LHE PORTABLE GENERATOR MODEL SM11000LHE OPERATOR'S MANUAL PRINTED IN CANADA REV 190713 PART NUMBER: Z97076...
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Page 2: Table Of Contents
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 SERVICE AND MAINTENANCE ..............30 6.1 SERVICE ....................30 6.1.1 FLUIDS AND LUBRICANTS ..............30 6.1.2 FLUIDS AND LUBRICANTS ..............30 6.1.3 SERVICE RECORD . -
Page 3: Warranty
WARRANTy WARRANTY Effective on products retailed on or after September 1, 2011. www.surgemaster.ca Register your product online at within 30 days of purchase to activate warranty. This product is warranted to be free of defects in materials and workmanship under normal use and service, for a period of Three (3) Years for Consumer One (1) Year for Commercial/Rental from the date of purchase, when operated and maintained in accordance with the Operating and Maintenance Instructions... -
Page 4: Inspection Report
SurgeMaster PORTABLE GENERATOR INSPECTION REPORT 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 SAFETy DEALER INSPECTION REPORT ____ Fasteners Tight ____ All Decals Installed ____ Check Electrical Connections ____ Guards and Shields Installed and Secured ____ Check Engine Fluid Levels ____ Review Operating and Safety Instructions 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. Date Dealer’s Rep. 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. -
Page 5: Serial Number Location
SERIAL NUMBER LOCATION 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. Generator Serial Engine Serial SM11000LHE SERIAL NUMBER LOCATION Model Number ____________________________________________________ Generator Serial Number ___________________________________________ Engine Serial Number _____________________________________________... -
Page 6: Introduction
INTRODUCTION 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, efficient 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. SM11000LHE 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. OPERATOR ORIENTATION - The directions left, right, front and rear, as mentioned throughout this manual, are determined when standing and looking at the electrical panel. -
Page 7: Safety
SAFETy SAFETy ALERT SyMBOL This Safety Alert symbol means The Safety Alert symbol identifies ATTENTION! BECOME ALERT! important safety messages on the yOUR SAFETy IS INVOLVED! 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. Why is SAFETY important to you? Accidents Disable and Kill 3 Big Reasons Accidents Cost Accidents Can Be Avoided DANGER SIGNAL WORDS: - Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury. This Note the use of the signal words DANGER, signal word is to be limited to the WARNING and CAUTION with the safety... -
Page 8: General Safety
GENERAL SAFETy SAFETy 1. Read and understand the Op- yOU are responsible for the SAFE operation erator’s Manual and all safety and maintenance of your SurgeMaster Port- signs before using, maintain- able Generator. yOU must ensure that you and ing, adjusting or cleaning the anyone else who is going to use, maintain or work Portable Generator. around the Portable Generator be familiar with the using and maintenance procedures and related 2. Have a first-aid kit available SAFETy information contained in this manual. for use should the need arise This manual will take you step-by-step through and know how to use it. your working day and alerts you to all good safety practices that should be used while using the Portable Generator. 3. Have a fire extinguisher available for use should the need arise and know Remember, yOU are the key to safety. Good how to use it. 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 EVERyONE using this equipment is familiar with the recommended using and maintenance proce- 4. Wear appropriate dures and follows all the safety precautions. Most protective gear. This accidents can be prevented. Do not risk injury or... -
Page 9: Equipment Safety Guidelines
EQUIPMENT SAFETy GUIDELINES 1. Safety of the operator and bystanders is one 7. Never exceed the limits of a piece of machin- of the main concerns in designing and de- ery. If its ability to do a job, or to do so safely, is in question - DON'T TRy IT. veloping equipment. However, every year many accidents occur which could have been avoided by a few seconds of thought and a 8. Do not modify the equipment in any way. Un- more careful approach to handling equipment. authorized modification may result in serious You, the operator, can avoid many accidents injury or death and may impair the function by observing the following precautions in this and life of the equipment. section. To avoid personal injury or death, study the following precautions and insist 9. In addition to the design and configuration of those working with you, or for you, follow this implement, including Safety Signs and them. Safety Equipment, hazard control and ac- cident prevention are dependent upon the 2. In order to provide a better view, certain awareness, concern, prudence, and proper photographs or illustrations in this manual training of personnel involved in the operation, may show an assembly with a safety shield transport, maintenance, and storage of the removed. However, equipment should never machine. Refer also to Safety Messages and be used in this condition. Keep all shields in operation instruction in each of the appropri-... -
Page 10: Safety Training
SAFETy TRAINING SAFETy SIGNS 1. Keep safety signs clean and legible at all 1. Safety is a primary concern in the design and manufacture of our products. Unfortunately, times. our efforts to provide safe equipment can be wiped out by a single careless act of an 2. Replace safety signs that are missing or have operator or bystander. become illegible. 2. In addition to the design and configuration of 3. Replaced parts that displayed a safety sign should also display the current sign. equipment, hazard control and accident pre- vention are dependent upon the awareness, concern, prudence and proper training of 4. Safety signs displayed in Section 3 each have a part number in the lower right hand corner. personnel involved in the operation, transport, maintenance and storage of this equipment. Use this part number when ordering replace- ment parts. 3. It has been said, "The 5. Safety signs are available from your author- best safety feature is an ized Distributor or Dealer Parts Department or informed, careful opera- the factory. tor." We ask you to be that kind of an operator. It is the operator's responsibility to read and under- How to Install Safety Signs:... -
Page 11: Preparation
PREPARATION MAINTENANCE SAFETy 1. Never use the engine and machine until you 1. Good maintenance is your responsibility. Poor have read and completely understand this maintenance is an invitation to trouble. manual, the Engine Operator's Manual and each of the Safety Messages found on the 2. Follow good shop practices. safety signs on the engine and machine. - Keep service area clean and 2. Personal pro- dry. tection equip- - Be sure electrical ment including outlets and tools hard hat, safety are properly glasses, safety grounded. shoes, and - Use adequate gloves are rec- light for the job at ommended dur- hand. ing assembly, installation, operation, adjustment, maintain- 3. Make sure there is ing, repairing, removal, cleaning, or moving plenty of ventilation. Never operate the en- the unit. Do not allow long hair, loose fitting... -
Page 12: Operating Safety
OPERATING SAFETy REFUELING SAFETy 1. Read and understand operator's manual before 1. Handle fuel with care. It is highly flammable. starting. Review safety instructions annually. 2. Allow engine to cool for 5 minutes before refu- 2. Stop and disable engine, remove ignition key elling. Clean up spilled fuel before restarting and place in your pocket and wait for all mov- engine. ing parts to stop before servicing, adjusting or repairing. 3. Do not refuel the machine while smoking or when 3. To prevent electrical shocks, do not operate near open flame or sparks. this generator in the rain or with wet hands. It should be grounded in damp or highly conduc- 4. Fill fuel tank outdoors. tive conditions. -
Page 13: Gas Motor Safety
2.11 GAS MOTOR SAFETy 14. DO NOT crank engine with spark plug removed. If engine is flooded, crank until engine starts. BEFORE STARTING ENGINE, READ 15. DO NOT strike flywheel with a hard object or AND UNDERSTAND THE OPERATING metal tool as this may cause flywheel to shatter AND MAINTENANCE INSTRUCTIONS in operation. Use proper tools to service engine. THAT CAME WITH yOUR ENGINE. 16. DO NOT operate engine without a muffler. Inspect periodically and replace, if necessary. If engine WARNING: DO NOT is equipped with a muffler deflector, inspect pe- riodically and replace, if necessary with correct 1. DO NOT run engine in an enclosed area. Ex-... -
Page 14: Sign-Off Form
2.12 SIGN-OFF FORM SurgeMaster follows the general Safety Standards specified 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 unqualified 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. SIGN-OFF FORM DATE EMPLOyEES SIGNATURE EMPLOyERS SIGNATURE... -
Page 15: Safety Sign Locations
SAFETy SIGN LOCATIONS 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! • Read and understand operator's manual before starting. Review safety instruc- tions annually. • 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. •... -
Page 16: Assembling
ASSEMBLING The machine comes from the factory in a shipping crate and configuration. A lways 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 sufficient clearance to access the machine from all sides. TyPICAL CRATING 3. Remove the lid and lay to the side. 4. Use a hoist or a crane to lift the unit out of its crate. -
Page 17: Install Battery
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. Attach cable from the starter solonoid 3. Lay out components. to positive (+) battery post and tighten 4. Position battery in its tray. sucurely. 5. Install the threaded "J" hooks into the bat- 9. Attach the cable from the ground post on tery tray. the starter to the negative (-) post on the battery (neutral is bonded to the frame) Hold Down Strap Wing Nut "J" Hook Battery Cable Starter Ground Post (-) Starter Solenoid (+) 36 Ah battery is recommended BATTERY SAFETY 1. Wear gloves and safety glasses or face shield 5. Keep all sparks and flames away from batter- when working on or near batteries. -
Page 18: Operation
OPERATION OPERATING SAFETy • Read and understand operator's manual before • Do not refuel the engine while it is in operation starting. Review safety instructions annually. or still hot. Do not refuel the engine near open flames, pilot lights or sparking electrical devices • Stop and disable engine, remove ignition key (e.g. power tools, welders or grinders). Do not and place in your pocket and wait for all mov- operate the generator near flammable products. ing parts to stop before servicing, adjusting or repairing. • The engine should be refuelled in a well-lit area. Avoid fuel spillage. • To prevent electrical shocks, do not operate this generator in the rain or with wet hands. It • Never allow children or unauthorized people should be grounded in damp or highly conduc- to operate or be around this machine. tive conditions. • Keep the working area clean and free of de- • Close and secure all guards, deflectors and bris to prevent tripping. Operate only on level shields before starting and operating. -
Page 19: Machine Components
MACHINE COMPONENTS T h e S u r g e M a s t e r S M 11 0 0 0 L H E P o r t - The unit is designed to provide 120 V or 240 V 60 Hz able Generator consists of a 20 hp Hon- power as a back up power supply at a remote location. -
Page 20: Machine Break-In
MACHINE BREAK-IN PRE-OPERATION CHECKLIST Although there are no operational restrictions on the Efficient and safe operation of the SurgeMaster Portable Generator when used for the first time, it is Portable Generator requires that each operator recommended that the following mechanical items reads and understands the using procedures and be checked: all related safety precautions outlined in this sec- tion. A pre-operation checklist is provided for the A. After operating for 1 hour: operator. It is important for both the personal safety and maintaining good mechanical condition that this 1. Re-torque all fasteners and hardware. checklist is followed. -
Page 21: Controls
CONTROLS Before starting to work, all operators should famil- iarize themselves with the location and function of controls. This applies to all models. 5.51 ENGINE: Read the engine manufacturers operator's manual before starting for more detailed instructions. Ignition Switch: This key operated switch controls the electric power to the engine. OFF - Turn key fully counterclockwise to stop the electrical system power and turn the engine off. ON - Turn clockwise 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 Choke engage the starter solenoid and start the engine. Release the key when the engine starts and it will return to the RUN position. Choke: This push/pull knob controls the position of the choke. Pull the knob out to close the choke for starting when the engine is cold. Ignition Push the knob in to open the choke as the engine warms. Always push the knob fully in Oil Alert HOURS 1/10 when operating the machine. Hour Meter Oil Alert: Honda GX630 The Oil Alert system is designed to prevent... -
Page 22: Electrical Controls:sm11000Lhe
5.52 ELECTRICAL CONTROLS:SM11000LHE SM11000LHE A. These two outlets (5-20R) are used to provide E. These 20 Amp breakers are used to protect the 120 Volt, 20 Amp power. 20 Amp 120 Volt outlets (A). Push the switch to reset. B. This outlet (L5-30) is used to provide 120 Volt, F. These 30 Amp circuit breakers protects the two 30 Amp power. 30 A mp out lets. (B&C). Push the switch to reset. C. This outlet (L14-30) is used to provide 120/240 G. Main Switch / 50 Amp breaker is the master Volt, 30 Amp power . overload for the generator. Move the switch up D. This outlet (14-50R) is used to provide 120/240 to engage and down to disengage the breaker. Volt, 50 Amp power. IMPORTANT A circuit breaker that trips repeatedly may indicate a... -
Page 23: Field Operation
FIELD OPERATION OPERATING SAFETy • Read and understand operator's manual before • Do not refuel the engine while it is in operation starting. Review safety instructions annually. or still hot. Do not refuel the engine near open flames, pilot lights or sparking electrical devices • Stop and disable engine, remove ignition key (e.g. power tools, welders or grinders). Do not and place in your pocket and wait for all mov- operate the generator near flammable products. ing parts to stop before servicing, adjusting or repairing. • The engine should be refuelled in a well-lit area. Avoid fuel spillage. • To prevent electrical shocks, do not operate this generator in the rain or with wet hands. It • Never allow children or unauthorized people should be grounded in damp or highly conduc- to operate or be around this machine. tive conditions. • Keep the working area clean and free of de- • Close and secure all guards, deflectors and bris to prevent tripping. Operate only on level... -
Page 24: Emergency Stopping
Use the ignition key to engage the starter. • Immediately switch off the main breaker e. Pull out the choke if the engine is cold or • Turn the engine off. hasn't been run for awhile. Correct the condition before resuming work and re-starting the engine. f. Run the engine until it warms and the choke is completely closed. 7. Terrain: g. Turn the appliance on or plug in the electri- The generator works well in a wide variety of cal load. operating conditions but it should always be positioned on the level. When the frame is level, fuel spillage is minimized and the gas tank capacity is maximized. Do not operate unless the frame is level. SM11000LHE... -
Page 25: Electrical Loads
8. Weather: 10. Electrical Component Condition: a. Do not operate in the rain or with wet hands. Keep the generator and work area dry to Always use electrical components that are in prevent shocks and shorts. Always ground good condition. Do not use electrical cords, the frame when operating in damp or wet plugs and connectors that are frayed, damaged, conditions. cracked or not in good condition. Electrical components that are not in good condition can b. Do not operate at temperatures above lead to shocks, shorts or sparking. Any of these... - Page 26 • The two 120 volt 20 amp GFCI (5-20R) outlets remember about electrical hazards include but are each protected by a 20 amp pop up circuit are not limited to: breaker. a. Keep all electrical components in good • The 120 volt 30 amp (L5-30) and the 120/240 condition. volt 30 amp (L14-30) receptacles are each protected by a 30 amp pop up breaker. If this b. Do not operate with frayed, cracked or breaker trips then the 30 amp circuit will be damaged parts. off. • The 120/240 volt 50 amp (6-50R & 14-50R) c. Ground the frame if operating in damp or receptacles are protected by a 50 amp wet conditions. breaker, which also serves as the main off/on switch. If this breaker trips all the circuits will d. Do not operate with wet hands. be off. IMPORTANT A circuit breaker that trips repeatedly may indicate a problem. SM11000LHE 50 Amp 20 Amp 30 Amp...
- Page 27 14. Operating Hints: a. Position frame on a level area to minimize d. Always ground the frame to minimize the the chance of spilling fuel and maximize the chance of sparks, shocks or shorts. This is fuel capacity of the tank. Spilled fuel can be very important in damp, wet or rainy condi- ignited by a spark from the electrical power tions. system. e. Position the generator under cover to protect b. Do not refuel while the engine is running. Wait it from rain or bad weather. until the unit has cooled before refuelling. f. Do not operate when the ambient tempera- c. Keep the working area neat and clean to pre- ture exceeds 100° F (39° C) to prevent over- vent slipping and tripping. Prevent accidents heating. at the work site. g. Do not cover the unit during operation to prevent overheating.
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Page 28: Moving
MOVING The generator is designed to be easily moved from one location to another. Review the following details on how the unit can be moved: Lift Eye 1. Lift Eye: The frame is designed with a lift eye that pro- vides an attach point for moving with an "A" frame, forklift, crane or other lifting system. Fold down handle 2. Wheel Kit: The SM1000LHE standard feature includes a wheel kit to make movement around the work area easier and safer. Kit consists of a fold down handle and 13" pneumatic tires mount- ed on an axle. 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. Fuel Line Shut- b. Turn the fuel line off. -
Page 29: Storage
STORAGE 5.8.2 REMOVING FROM STORAGE OPERATING SAFETy this procedure: • Store the unit in an area away from human 1. Remove the tarpaulin if covered. activity. 2. Install and connect the battery. • Do not permit children to play on or around the stored machine. 3. Bring the ignition key. • Store the unit in a dry, level area. Support the frame with planks if required. 4. Review and follow the pre-operation checklist. 5.8.1 PLACING IN STORAGE After the season's use or when the machine will not IMPORTANT... -
Page 30: Service And Maintenance
SERVICE AND MAINTENANCE SERVICE MAINTENANCE SAFETy 6.1.1 FLUIDS AND LUBRICANTS • Good maintenance is your responsibility. 1. Grease: Poor maintenance is an invitation to trouble. Use an SAE multipurpose high temperature grease with extreme pressure (EP) perform- • Follow good shop practices. ance. Also acceptable is an SAE multipur- pose lithium base grease. Keep service area clean and dry. Be sure electrical outlets and tools are 2. Engine Oil: properly grounded. See Honda engine owners manual for full de- Use adequate light for the job at hand. tail on oil type specific to operating conditions and capacity. • Make sure there is plenty of ventilation. Nev- er operate the engine of the towing vehicle in 3. Engine Gasoline: a closed building. The exhaust fumes may See Honda engine owners manual for full cause asphyxiation. -
Page 31: Service Record
6.1.3 SERVICE RECORD See Lubrication and Maintenance sections for details of service. Copy this page to continue record. ACTION CODE CHECK CLEAN R REPLACE CHANGE HOURS SERVICED 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 CH Engine Oil Filter R Fuel Filter R Air Cleaner Annually CL Machine MAINTENANCE By following a careful service and maintenance program for your machine, you will enjoy many years of trouble -free operation. -
Page 32: Trouble Shooting
TROUBLE SHOOTING The SurgeMaster Portable Generator is designed to generate up to 10,000 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 or dealer. Before you call, please have this Operator's Manual from your unit and serial number ready. PROBLEM CAUSE SOLUTION Engine doesn't start. No fuel. Fill fuel tank. Fuel filter plugged. Replace fuel filter. Weak battery. Recharge or replace battery. Loaded electrically. Remove electric load. Breakers tripping. Electrical load too high. Reduce electrical load. -
Page 33: Specifications
SPECIFICATIONS MECHANICAL SM11000HLHE Engine 20 hp / GX630 Maximum Watts 12,000 Continuous Watts 10,000 Maximum Amps 100 / 50 120 V / 240 V Continuous Amps 84 / 42 Frequency 60 Hz Voltage 120 / 240 Fuel Tank Capacity 40 litres Run Time 1/2 Load 10 hours Full Load 7 hours Weight 348 lbs Dimensions 32" L x 22" W x 29" H... -
Page 34: 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 SAE 5 Diameter SAE 2 SAE 8 (N.m) (lb-ft) (N.m) (lb-ft) "A" (N.m) (lb-ft) 1/4" 5/16" 3/8" 7/16" 1/2" 9/16" 5/8" 3/4" 7/8" 1" 1320 METRIC TORQUE SPECIFICATIONS Bolt Torque* Bolt 10.9... -
Page 35: Index
INDEx Symbols LIFT EyE ............. 19, 29 12 KVA ALTERNATOR ........19 LOUD NOISE ............. 11 20 AMP ...............27 LUBRICANTS ............31 30 AMP ...............27 50 AMP ...............27 MAIN SWITCH ...........19 MODEL NUMBER ..........5 ASABE ...............14 OFF ..............21 BATTERy ............17 OIL ALERT ............21 OIL USE HOURS METER ........19 CAUTION .............7 ON ..............21...
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