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Page 23 was the only update required, it shows the layout of the various control
panels.
4144 Boomer Line · St. Clements, On · N0B 2M0 · Canada
PORTABLE GENERATORS
SM2500CH
SM2500CH
SM3000CH
SM5000CH
Do not attempt to start or operate the generator without
thoroughly reviewing this manual for safe and proper operation.
Keep this manual with the Generator at all times
PRINTED IN CANADA
REV 0160714
EMB Manufacturing Inc.
Ph: (519) 699-9283 · Fax: (519) 699-4146
www.surgemaster.ca
OPERATOR'S MANUAL
SM3000SU
Before putting the generator into service:
SM3000GFI
SM3000CH
SM3000SU
SM3000GFI
SM5000GFI
EMB MFG INC.
BY
SM5000GFI
SM5000CH
PS
C
US
®
CERTIFIED.
ELECTRICAL SAFETY
PART NUMBER: Z97037
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Summary of Contents for Surge master SM3000SU
- Page 1 Page 23 was the only update required, it shows the layout of the various control panels. EMB Manufacturing Inc. 4144 Boomer Line · St. Clements, On · N0B 2M0 · Canada Ph: (519) 699-9283 · Fax: (519) 699-4146 www.surgemaster.ca PORTABLE GENERATORS OPERATOR'S MANUAL SM3000GFI SM3000SU SM5000GFI SM3000CH SM2500CH SM5000CH SM2500CH SM3000SU SM3000CH SM3000GFI...
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Page 2: Table Of Contents
MAINTENANCE ........32 4.5.2 ELECTRICAL PANEL....... 23 6.2.1 GENERAL MAINTENANCE ....32 SM2500CH & SM300CH ..... 23 6.2.2 ENGINE MAINTENANCE ....32 SM3000SU & SM3000GFI ....23 6.2.3 ALTERNATOR MAINTENANCE ..32 SM5000GFI ........23 SPECIFICATIONS ........33 SM5000CH .......... 23 MECHANICAL........33 CIRCUIT BREAKERS:......24 BOLT TORQUE ........34... -
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: Surgemaster
SurgeMaster Emergency Power Series: SM2500CH, SM3000CH, SM5000CH Contractor Ready Series SM3000SU, SM3000GFI, SM5000GFI DELIVERY INSPECTION REPORT To activate warranty, register your product online at www.surgemaster.ca _________________________________________ Pre-Delivery Inspection Customer’s Name Inspect for damage from shipping, immediately contact the shipping company if damage is found. -
Page 5: Serial Number Location
SERIAL NUMBER LOCATION Always reference the serial number of your SurgeMaster generator when ordering parts or requesting ser- vice or other information. The serial number plate is located where indicated. Please mark the numbers in the spaces provided for easy reference. (Serial label location is the same for ALL models) Serial Location SERIAL NUMBER LOCATION Emergency Power Series or Contractor ReadySeries Portable Gas Generator... -
Page 6: Introduction
OPERATOR ORIENTATION - The directions left, right, front and rear, as mentioned throughout this manual, are determined when facing the control panel SM2500CH SM3000SU SM3000CH SM3000 GFI SM5000CH &... -
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! Wallenstein Generator and in the manual. When you see this symbol, be alert to the possibility of personal injury or death. -
Page 8: Safety Do's & Don'ts
SAFETY YOU are responsible for the SAFE operation and • DO review safety related items annually with maintenance of your Wallenstein Portable Gen- all personnel who will operating or maintaining erator. YOU must ensure that you and anyone the generator else who is going to use, maintain or work around •... -
Page 9: Equipment Safety Guidelines
EQUIPMENT SAFETY GUIDELINES Safety of the operator and bystanders is one of the main concerns in designing and developing equip- ment. 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 acci- dents by observing the following precautions in this section. -
Page 10: Safety Training
SAFETY TRAINING 5. Know your controls and how to stop the 1. Train all new personnel and review instruc- engine and machine quickly in an emergency. tions frequently with existing workers. Safety Read this manual and the one provided with is a primary concern in the design and manu- your engine. -
Page 11: Preparation
PREPARATION 1. Never use the engine and machine until the 4. Clear working area of stones, branches or operators have been adequately trained in the hidden obstacles that might be hooked or safe operation of the machine and have read snagged, causing injury or damage. -
Page 12: Maintenance Safety
MAINTENANCE SAFETY 1. Good maintenance is your responsibility. Poor 9. An appropriate fire extin- maintenance is an invitation to trouble. guisher (electrical fires) and first aid kit should be 2. Follow good shop practices. kept readily accessible • Keep service area clean and dry. while performing mainte- •... -
Page 13: Operating Safety
OPERATING SAFETY 1. Please remember it is important that you read 11. Plug appliances directly into generator or use and heed the safety signs on the generator. a heavy-duty outdoor-rated extension cord. Clean or replace all safety signs if they can- Make sure entire extension cord is free of cuts not be clearly read and understood. -
Page 14: Transport Safety
TRANSPORT SAFETY 2.10 ELECTRICAL SAFETY 1. Comply with Provincial / state and local laws 1. The generator produces governing safety and transporting of machin- enough electric power to cause ery on public roads. a serious shock or electrocution 2. Do not exceed a safe travel speed. Slow if misused. -
Page 15: 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. -
Page 16: Sign-Off Form
2.12 SIGN-OFF FORM Wallenstein follows the general Safety Standards specified by the American Society of Agricultural and Biological Engineers (ASABE) and the Occupational Safety and Health Administration (OSHA). Any- one 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. -
Page 17: Safety Signs
SAFETY SIGNS 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 in Section 3 each have a part number displayed with it. Use this part number when ordering replacement parts. - Page 18 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. •...
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Page 19: Operation & Features
OPERATION & FEATURES OPERATING SAFETY • Read and understand operator's manual before • Do not refuel the engine while it is in opera- starting. Review safety instructions annually. tion or still hot. Do not refuel the engine near open flames, pilot lights or sparking electrical •... -
Page 20: Machine Components
SM2500CH 160cc 2.9 kVA 2100 2500 SM3000CH 160cc 2.9 kVA 2700 3000 SM5000CH 270cc 4.9 kVA 4500 5000 SM3000SU 169cc 2.9 kVA 2500 3000 SM3000GFI 160cc 2.9 kVA 2700 3000 SM5000GFI 270cc 4.9 kVA 4500 5000 Note: All SurgeMaster generators are CSA certified and have the safety feature of the neutral conductor bonded to the frame, an OSHA requirement when using portable electrical equipment on job sites. -
Page 21: Machine Break-In
MACHINE BREAK-IN PREOPERATION CHECKLIST Although there are no operational restrictions on Efficient and safe operation of the SurgeMaster the portable generator when used for the first Portable Generator requires that each operator time, it is recommended that the following me- reads and understands the use procedures and all related safety precautions outlined in this section. -
Page 22: Controls
Rope Fuel SM3000CH & SM3000GFI - GX160 Tank Choke Fuel Tank On / Off Choke On / Off Fuel Shut-off Fuel Shut-off Starting Rope SM3000SU - EX170 Starting Rope SM5000CH & SM5000GFI - GX270... -
Page 23: Electrical Panel
20 amp pop up breaker. 2 x 125v 20 amp duplex receptacles (5-20R) SM3000SU & SM3000GFI 2 x 20 amp pop Two duplex GFCI outlets provide 120 v, each up breaker protected by a 20 Amp pop up breaker. -
Page 24: Circuit Breakers
CIRCUIT BREAKERS: Outlets on the electrical panel are protected Circuit Breaker with circuit breakers to prevent overloading the circuit. If a breaker trips, reduce the load before re-setting the breaker. GFCI • If a breaker trips,: • the breaker reset pops out •... -
Page 25: Electrical Load
ELECTRICAL LOAD RESISTIVE LOAD A resistive load is lighting, hot plate, TV, etc, 4.6.1 BALANCING LOADS Resistive loads generally will not spike and start- Balancing loads section applies to model ing wattage is the same as running wattage. (See SM5000CH (120v/240v.) wattage chart) When operating your SurgeMaster generator CONTINUOUS WATTAGE... -
Page 26: Wattage Chart
4.6.4 WATTAGE CHART The chart below contains general wattage information, and is intended to be used as a guide only. For some electrical, and electronic appliances, you can determine the power needed by looking at the data tag supplied by the manufacturer. Most products and all electrical motors should have a data tag attached to their bodies that give volts and amps and may contain wattage information. -
Page 27: Field Operation
FIELD OPERATION OPERATING SAFETY • Read and understand operator's manual before • Do not refuel the engine while it is in opera- starting. Review safety instructions annually. tion or still hot. Do not refuel the engine near open flames, pilot lights or sparking electrical •... -
Page 28: Start
START 5.2.1 STARTING THE GENERATOR: 5.2.6 ELECTRICAL LOADS: • Ensure the main power switch / breaker is The generator is ideally suited to camping, in the "off" position or turn all the appliances boating, farm, household, workshop, con- or electrical loads off. struction site or anywhere that back-up power is required. -
Page 29: Residential
RESIDENTIAL The most economical way to supply power during a power outage is to use a portable generator and run extension cords into the house to power chosen appliances. Never connect a generator to a house electrical system without an appropriate transfer switch. Known as "backfeeding"... -
Page 30: Storage
STORAGE 5.5.2 REMOVING FROM STORAGE STORAGE SAFETY When removing this machine from storage, follow • Store the unit in an area away from human this procedure: activity, or children playing • Do not store near any tool, machine, appli- 1. Remove the tarpaulin if covered. ance that produces flame or sparks. -
Page 31: Service And Maintenance
Fuel Tank Capacity: ately. SM2500CH 3.1 L (3.3 US qt) 4. If fittings will not take grease, remove and SM3000SU 3.6 L (1.0 US gal) clean thoroughly. Also clean lubricant pas- SM3000GFI 3.1 L (3.3 US qt) sageway. Replace fittings if necessary. -
Page 32: Maintenance
MAINTENANCE By following a careful service and maintenance program for your machine, you will enjoy many years of trouble free operation. Ensure all operators understand how to put the machine in safe condition before working with this machine, DANGER • Flip main switch "off" or disconnect all loads •... -
Page 33: Specifications
SPECIFICATIONS MECHANICAL Emergercy Power Series Contractor Ready Series Economy Generators SM2500CH SM3000CH SM5000CH SM3000SU SM3000GFI SM5000GFI 2500 3000 5000 3000 3000 5000 Maximum watts Continuous watts 2100 2700 4500 2500 2700 4500 21.6 27.5 41.5 27.5 27.5 41.5 Maximum amps (120-V) Continuous amps (120-V) 37.5... -
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... -
Page 35: Trouble Shooting
TROUBLE SHOOTING SurgeMaster generators are designed with high quality engines combined with tested and tough 120 / 240v alternators to produce a system that very reliable and robust. In the following page, we have listed many of the causes and solutions to the problems that you may encounter. -
Page 36: Accessories
ACCESSORIES Call your dealer for pricing and availability #WK210 TWO WHEEL KIT WITH 10'' TIRES #WK214 TWO WHEEL KIT WITH 14'' TIRES For all models: A must have add on kit for true portability! #WK210 Shown mounted on SM3000GFI Generator Extention cord, the right length and size, to make the most of your generator. - Page 37 INDEX LUBRICANTS ..............31 Symbols 5-20R ..................23 MAXIMUM WATTAGE ............25 ACCESSORIES ..............36 NEUTRAL BONDED TO FRAME ........6, 29 AFTER OPERATING FOR 1 HOUR ........21 NOISE .................. 11 AFTER OPERATING FOR 8 HOURS ........21 AIR DISCHARGE ..............21 OIL ..................
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