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EMB MFG INC.
BY
EMB Manufacturing Inc.
4144 Boomer Line · St. Clements, On · N0B 2M0 · Canada
Ph: (519) 699-9283 · Fax: (519) 699-4146
www.embmfg.com
SMWDC160
SMWDC190EA
SMWDC190E
PORTABLE WELDER/GENERATOR
MODELS SMWDC160, SMWDC190E
AND SMWDC190EA
OPERATOR'S MANUAL
Before putting the generator / welder into service:
Do not attempt to start or operate the generator without thoroughly reviewing
this manual for safe and proper operation.
Keep this manual with the
PS
machine at all times
C
US
®
250 CCA Battery is not Included
CERTIFIED.
ELECTRICAL SAFETy
PRINTED IN CANADA
REV 191213
PART NUMBER: Z97080
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Related Manuals for Surge master SMWDC160
Summary of Contents for Surge master SMWDC160
- Page 1 SMWDC160 SMWDC190EA SMWDC190E PORTABLE WELDER/GENERATOR MODELS SMWDC160, SMWDC190E AND SMWDC190EA OPERATOR'S MANUAL Before putting the generator / welder into service: Do not attempt to start or operate the generator without thoroughly reviewing this manual for safe and proper operation.
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Page 2: Table Of Contents
TABLE OF CONTENTS WARRANTy .............3 OPERATION ........19 INSPECTION REPORT ..........4 To ThE NEW oPERAToR .... 19 mAChINE ComPoNENTS .... 20 SERIAL NUMBER LOCATION ........5 mAChINE BREAk-IN ....21 INTRODUCTION .........6 PRE-oPERATIoN ChECkLIST ..21 SAFETy ............7 CoNTRoLS ........22 GENERAL SAFETY .........8 5.5.1 ENGINE CoNTRoLS .... -
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... -
Page 5: 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. SMWDC160 / SMWDC190E SMWDC190EA SERIAL NUMBER LOCATION Model Number ____________________________________________________... -
Page 6: Introduction
SMWDC160 / SMWDC190E SMWDC190EA This manual covers the Surgemaster Portable Generator models SmWDC160, SmWDC190E and SmWD- C190EA. 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 Surgemaster dealer or the Distributor if you need assistance, information or additional copies of the manuals. -
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. -
Page 8: General Safety
GENERAL SAFETy SAFETy 1. Read and understand the operator’s manual yOU are responsible for the SAFE operation and all safety signs before using, and maintenance of your Surgemaster Port- maintaining, adjusting or clean- able Generator. yOU must ensure that you and ing the Portable Generator. -
Page 9: Arc Welding Safety
ARC WELDING SAFETy Read and understand the operator’s manual and all safety signs before using, maintaining, adjusting or cleaning the Portable Generator. have only qualified persons install, use, or service all equipment. Do not use worn, damaged, under sized, or repaired cables. 2.2.1. -
Page 10: 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. -
Page 11: 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. -
Page 12: 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. -
Page 13: Operating Safety
OPERATING SAFETy REFUELLING 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. -
Page 14: Gas Motor Safety
2.12 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 15: Sign-Off Form
2.13 SIGN-OFF FORM Surgemaster follows the general Safety Standards specified by the occupational Safety and health Adminis- tration (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. -
Page 16: Safety Sign Locations
SAFETY AWARENESS. • Think SAFETY! Work SAFELY! SMWDC160 SMWDC190E DANGER! Using a generator indoors CAN kILL YoU IN mINUTES. Generator Exhaust contains carbon monoxide. -
Page 17: Assembling
ASSEMBLING The machine comes from the factory in a shipping crate and configuration. 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. -
Page 18: 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. -
Page 19: 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 •... -
Page 20: Machine Components
The battery and fuel tank idle relay for increased convenience. All control are mounted in the frame for convenient access. and power outlets are mounted on the end of the SmWDC190EA SmWDC160 / WDC190E SmWDC160 SmWDC190EA Circuit Breaker Engine... -
Page 21: 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-... -
Page 22: Controls
CONTROLS 5.5.1 ENGINE CoNTRoLS Before starting to work, all operators should famil- iarize themselves with the location and function of controls. Engine: Read the engine manufacturers operator's manual before starting for more detailed instructions. a. Ignition Switch: SMWDC190EA This key operated switch controls the electric power to the engine. -
Page 23: Electrical Controls
Refer to the welding manual provided for detailed information. e. 110 Volt, GFCI Outlets: These outlets are used SmWDC160 / SmWDC190E to provide 110 Volt, 15 Amp power 220 Volt, 30 Amp Outlet: This outlet is used to provide 220 Volt, 30 Amp power. -
Page 24: 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 •... - Page 25 4. Starting the Generator: 8. Welding a. Plug in power cords from appliances or Prepare for welding by connecting the weld out- loads. put cables to the weld output jacks. The output jacks are protected by a spring loaded cover. b.
- Page 26 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.
- Page 27 15 amp pop up circuit breaker. a. keep all electrical components in good condition. • SMWDC160 / 190E / 190EA: the 110/220 volt (L14-30) receptacle is protected by two 15 b. Do not operate with frayed, cracked or amp breakers.
- Page 28 14. Operating Hints: Welding is a specialized application that has its own set of operating requirements. Always keep the working area neat and clean to pre- consult with specialists in the field and read the vent slipping and tripping. Prevent accidents manual provided with your welding machine at the work site.
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Page 29: Moving
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. SmWDC160 / SmWDC190E b. Turn the fuel valve off. SmWDC190EA Fig. 14 ShUT-oFF VALVE (Typical) -
Page 30: 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. -
Page 31: Service And Maintenance
• Before working on this machine, shut off the Fuel Tank Capacity: engine, set the brake, and turn fuel valve SmWDC160 6.5 L (1.72 US Gal) off. SmWDC190E 6.5 L (1.72 US Gal) SmWDC190EA 21 L (5.5 US Gal) -
Page 32: 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 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... -
Page 33: 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. -
Page 34: Specifications
SPECIFICATIONS MECHANICAL WDC160 WDC190E WDC190EA GX390 389 cc Engine GX340 389 cc 3,500 Maximum Watts 3,000 Continuous Watts Maximum Amps 30 / 15 110 V / 220 V Continuous Amps 24 /12 110 V / 220 V 60 hz Frequency 110 / 220 Voltage 1.6 U.S.gal... -
Page 35: 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 36: Accessories
ACCESSORIES Call your dealer for pricing and availability #Z93204 U1 250CCA LAWN & GARDEN BATTERy For models: SMWDC190E & SMWDC190EA The perfect battery to reliably get your generator started. #Z93204... -
Page 37: Index
INDEx ASABE ...............14 LOUD NOISE ............. 11 AUTOMATIC IDLE CONTROL ....22, 27 LUBRICANTS ............31 BATTERy ............17 MODEL NUMBER ..........5 CAUTION .............7 OPERATING HINTS ...........28 CIRCUIT BREAKERS ........27 OPERATOR ORIENTATION ........6 COMPONENT CONDITION .......26 PROTECTIVE GEAR ...........8 DANGER ..............7 SAFETy ...............8 ELECTRICAL LOADS ........26 SIGNAL WORDS ..........7 EMERGENCy ............25...
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