PORTABLE GENERATORMODEL SM11000LHEOPERATOR'S MANUAL

SM11000LHE

PRINTED IN CANADAREV 190713 PART NUMBER: Z97076

EMB Manufacturing Inc.4144 Boomer Line · St. Clements, On · N0B 2M0 · Canada

Ph: (519) 699-9283 · Fax: (519) 699-4146 www.embmfg.com

BY EMB MFG INC.

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TABLE OF CONTENTSWARRANTy .................................................................................................................3INSPECTION REPORT ................................................................................................4SERIAL NUMBER LOCATION ....................................................................................51 INTRODUCTION .............................................................................................62 SAFETy ..........................................................................................................7

2.2 EQUIPMENTSAFETYGUIDELINES..........................................................92.3 SAFETYTRAINING...................................................................................102.5 PREPARATION..........................................................................................112.6 MAINTENANCESAFETY..........................................................................112.7 OPERATINGSAFETY...............................................................................122.8 REFUELINGSAFETY...............................................................................122.9 STORAGESAFETY...................................................................................122.10 BATTERYSAFETY....................................................................................122.11 GASMOTORSAFETY..............................................................................132.12 SIGN-OFFFORM......................................................................................14

3 SAFETy SIGN LOCATIONS .......................................................................154 ASSEMBLING .............................................................................................16

4.1 INSTALLBATTERY:...................................................................................175 OPERATION .................................................................................................18

5.1 TOTHENEWOPERATOROROWNER..................................................185.2 MACHINECOMPONENTS........................................................................195.3 MACHINEBREAK-IN................................................................................205.4 PRE-OPERATIONCHECKLIST................................................................205.5 CONTROLS...............................................................................................215.51 ENGINE:....................................................................................................215.52 ELECTRICALCONTROLS:SM11000LHE.................................................225.6 FIELDOPERATION...................................................................................235.7 MOVING....................................................................................................285.8 STORAGE.................................................................................................295.8.1 PLACINGINSTORAGE............................................................................295.8.2 REMOVINGFROMSTORAGE.................................................................29

6 SERVICE AND MAINTENANCE ..................................................................306.1 SERVICE...................................................................................................306.1.1 FLUIDSANDLUBRICANTS......................................................................306.1.2 FLUIDSANDLUBRICANTS......................................................................306.1.3 SERVICERECORD...................................................................................316.2 MAINTENANCE.........................................................................................31

7 TROUBLE SHOOTING .................................................................................328 SPECIFICATIONS ........................................................................................33

8.1 MECHANICAL............................................................................................338.2 BOLTTORQUE..........................................................................................34

INDEx.........................................................................................................................35

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WARRANTyWARRANTY

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

Register your product online at www.surgemaster.ca 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

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 adjustments3) Normal replacement of service items.4) Accessory items / parts not supplied by EMB MFG INC.5) Damages resulting from:

• misuse, negligence, accident, theft or fire• use of improper or insufficient fuel, fluids or lubricants • use of parts or after market accessories other than genuine EMB MFG INC. parts • modifications, 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 specified 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 profits. 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 difficulty 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 files).

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 specified herein.

EMB MFG Inc4144 Boomer Line, St Clements, ON N0B 2M0 Canada

Phone: 519-699-9283 Fax: 519-699-4146 : attention to Warranty DeptEmail: warranty@embmfg.com

WARRANTY IS VOID IF NOT REGISTERED

Three (3) Years for ConsumerOne (1) Year for Commercial/Rental

rev.091111

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____ AllDecalsInstalled____ GuardsandShieldsInstalledandSecured____ ReviewOperatingandSafetyInstructions

____ FastenersTight____ CheckElectricalConnections____ CheckEngineFluidLevels

SurgeMasterPORTABLE GENERATOR

INSPECTION REPORT

DateDealer’sRep.Signature

DateOwner'sSignature

TheaboveequipmentandOperator’sManualhavebeenreceivedbymeandIhavebeenthoroughlyinstructedastocare,adjustments,safeoperationandapplicablewarrantypolicy.

Thisformmustbefilledoutbythedealerandsignedbyboththedealerandthecustomeratthetimeofdelivery.

Customer’sName DealerName

Address Address

City,State/Province,Code City,State/Province,Code

PhoneNumber() PhoneNumber()

ContactName

Model

SerialNumber DeliveryDate

IhavethoroughlyinstructedthebuyerontheabovedescribedequipmentwhichreviewincludedtheOperator’sManualcontent,equipmentcare,adjustments,safeoperationandapplicablewarrantypolicy.

DEALER INSPECTION REPORT

SAFETy

To activate waranty, register your product online at www.embmfg.com

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SERIAL NUMBER LOCATIONAlwaysgiveyourdealertheserialnumberofyourSurgeMasterPortableGeneratorwhenorderingpartsorrequestingserviceorotherinformation.

Theserialnumberplateislocatedwhereindicated.Pleasemarkthenumbersinthespacesprovidedforeasyreference.

SERIAL NUMBER LOCATION

Model Number ____________________________________________________Generator Serial Number ___________________________________________Engine Serial Number _____________________________________________

SM11000LHE

Generator Serial

Engine Serial

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1 INTRODUCTIONCongratulationsonyourchoiceofanSurgeMasterPortableGeneratortocomplimentyouroperation.Thisequipmenthasbeendesignedandmanufacturedtomeettheneedsofadiscerningperson,operatororindustrythatneedsportableelectricalpower.

Safe,efficientandtroublefreeoperationofyourSurgeMasterPortableGeneratorrequiresthatyouandanyoneelsewhowillbeusingormaintainingthegenerator,readandunderstandtheSafety,Operation,MaintenanceandTroubleShootinginformationcontainedwithintheOperator'sManual.

ThismanualcoverstheSurgeMasterPortableGeneratorModelsSM11000LHE.UsetheTableofCon-tentsorIndexasaguidetolocaterequiredinformation.

Keepthismanualhandyforfrequentreferenceandtopassontonewoperatorsorowners.CallyourSurgeMasterdealerortheDistributerifyouneedassistance,informationoradditionalcopiesofthemanuals.

OPERATOR ORIENTATION -Thedirectionsleft,right,frontandrear,asmentionedthroughoutthismanual,aredeterminedwhenstandingandlookingattheelectricalpanel.

SM11000LHE

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2 SAFETySAFETy ALERT SyMBOL

WhyisSAFETYimportanttoyou?

TheSafetyAlertsymbolidentifiesimportantsafetymessagesontheSurgeMasterPortableGeneratorandinthemanual.Whenyouseethissymbol,bealerttothepossibilityofpersonalinjuryordeath.Followtheinstructionsinthesafetymessage.

ThisSafetyAlertsymbolmeans ATTENTION! BECOME ALERT! yOUR SAFETy IS INVOLVED!

Accidents Disable and Kill Accidents Cost Accidents Can Be Avoided

3 Big Reasons

Ifyouhaveanyquestionsnotansweredinthismanualorrequireadditionalcopiesorthemanualisdamaged,pleasecontactyourdealerorSurgeMaster,4144BoomerLine,St.Clements,ON,N0B2M0.Phone(519)699-9283orFax(519)699-4146.

DANGER - Indicatesanimminentlyhazardoussituationthat,ifnotavoided,willresultindeathorseriousinjury.Thissignalwordistobelimitedtothemostextremesituationstypicallyformachinecomponentswhich,forfunc-tionalpurposes,cannotbeguarded.

WARNING - Indicatesapotentiallyhazardoussituationthat,ifnotavoided,couldresultindeathorseriousinjury,andincludeshazardsthatareexposedwhenguardsareremoved.Itmayalsobeusedtoalertagainstunsafepractices.

CAUTION - Indicatesapotentiallyhazardoussituationthat,ifnotavoided,mayresultinminorormoderateinjury.Itmayalsobeusedtoalertagainstunsafepractices.

SIGNAL WORDS:

NotetheuseofthesignalwordsDANGER, WARNING andCAUTIONwiththesafetymessages.Theappropriatesignalwordforeachmessagehasbeenselectedusingthefollowingguide-lines:

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2.1 GENERAL SAFETy

1. ReadandunderstandtheOp-erator’sManualandallsafetysignsbeforeusing,maintain-ing,adjustingorcleaningthePortableGenerator.

2. Have a first-aid kit availableforuseshouldtheneedariseandknowhowtouseit.

3. Haveafireextinguisheravailableforuseshouldtheneedariseandknowhowtouseit.

4. Wear appropriateprotectivegear.Thislistincludesbutisnotlimitedto:

- Ahardhat- Protective shoeswithslip resistantrubber soles- Protectiveglasses, gogglesorfaceshield- Heavygloves- HearingProtection

5. Installandsecureallguardsbeforestarting.

6. Wear suitable ear protectionfor prolonged exposure toexcessivenoise.

7. Stopanddisableengine, remove ignitionkeyandplaceinyourpocketandwaitforallmovingparts to stop before servicing, adjusting orrepairing.

8. Clear the area of people, especially smallchildren,beforeusingtheunit.

9. Review safety related items annually with allpersonnelwhowilloperatingormaintainingthePortableGenerator.

SAFETyyOUareresponsiblefortheSAFEoperationandmaintenanceofyourSurgeMasterPort-ableGenerator.yOUmustensurethatyouandanyoneelsewhoisgoingtouse,maintainorworkaroundthePortableGeneratorbefamiliarwiththeusingandmaintenanceproceduresandrelatedSAFETyinformationcontainedinthismanual.Thismanualwilltakeyoustep-by-stepthroughyourworkingdayandalertsyoutoallgoodsafetypracticesthatshouldbeusedwhileusingthePortableGenerator.

Remember,yOUarethekeytosafety.Goodsafetypracticesnotonlyprotectyoubutalsothepeoplearoundyou.Makethesepracticesawork-ingpartofyoursafetyprogram.BecertainthatEVERyONEusingthisequipmentisfamiliarwiththerecommendedusingandmaintenanceproce-duresandfollowsallthesafetyprecautions.Mostaccidentscanbeprevented.Donotriskinjuryordeathbyignoringgoodsafetypractices.

• PortableGeneratorownersmustgiveoperat-inginstructionstooperatorsoremployeesbeforeallowingthemtooperatethemachine,andatleastannuallythereafter.

• ThemostimportantsafetydeviceonthisequipmentisaSAFEoperator.Itistheop-erator’sresponsibilitytoreadandunderstandALLSafetyandOperatinginstructionsinthemanualandtofollowthese.Mostaccidentscanbeavoided.

• Apersonwhohasnotreadandunderstoodallusingandsafetyinstructionsisnotqualifiedtousethemachine.Anuntrainedoperatorexposeshimselfandbystanderstopossibleseriousinjuryordeath.

• Donotmodifytheequipmentinanyway.Unauthorizedmodificationmayimpairthefunctionand/orsafetyandcouldaffectthelifeoftheequipment.

• ThinkSAFETY!WorkSAFELY!

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2.2 EQUIPMENT SAFETy GUIDELINES

1. Safetyoftheoperatorandbystandersisoneofthemainconcernsindesigningandde-velopingequipment.However,everyyearmanyaccidentsoccurwhichcouldhavebeenavoidedbyafewsecondsofthoughtandamorecarefulapproachtohandlingequipment.You,theoperator,canavoidmanyaccidentsbyobservingthefollowingprecautionsinthissection.Toavoidpersonalinjuryordeath,studythefollowingprecautionsandinsistthoseworkingwithyou,orforyou,followthem.

2. Inordertoprovideabetterview,certainphotographsorillustrationsinthismanualmayshowanassemblywithasafetyshieldremoved.However,equipmentshouldneverbeusedinthiscondition.Keepallshieldsinplace.Ifshieldremovalbecomesnecessaryforrepairs,replacetheshieldpriortouse.

3. Replaceanysafetysignorinstructionsignthatisnotreadableorismissing.Locationofsuchsafetysignsisindicatedinthismanual.

4. Neverusealcoholicbeveragesordrugswhichcanhinderalertnessorcoordinationwhileus-ingthisequipment.Consultyourdoctoraboutusingthismachinewhiletakingprescriptionmedications.

5. Under no circumstances should young children be allowed to work with this equipment. Do not allow persons to use or assemble this unit until they have read this manual and have developed a thorough understanding of the safety precautions and of how it works.Reviewthesafetyinstructionswithallusersannually.

6. Thisequipmentisdangeroustochildrenandpersonsunfamiliarwithitsoperation.Theoperatorshouldbearesponsible,properlytrainedandphysicallyablepersonfamiliarwithmachineryandtrainedinthisequipment'soperations.Iftheelderlyareassistingwithwork,theirphysicallimitationsneedtoberecognizedandaccommodated.

7. Neverexceedthelimitsofapieceofmachin-ery.Ifitsabilitytodoajob,ortodososafely,isinquestion-DON'T TRy IT.

8. Donotmodifytheequipmentinanyway.Un-authorizedmodificationmayresultinseriousinjuryordeathandmayimpairthefunctionandlifeoftheequipment.

9. Inadditiontothedesignandconfigurationofthisimplement,includingSafetySignsandSafetyEquipment,hazardcontrolandac-cidentpreventionaredependentupontheawareness,concern,prudence,andpropertrainingofpersonnelinvolvedintheoperation,transport,maintenance,andstorageofthemachine.ReferalsotoSafetyMessagesandoperationinstructionineachoftheappropri-atesectionsoftheengineandmachinemanu-als.PaycloseattentiontotheSafetySignsaffixedtotheengineandthemachine.

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2.3 SAFETy TRAINING

1. Safetyisaprimaryconcerninthedesignandmanufactureofourproducts.Unfortunately,oureffortstoprovidesafeequipmentcanbewipedoutbyasinglecarelessactofanoperatororbystander.

2. Inadditiontothedesignandconfigurationofequipment,hazardcontrolandaccidentpre-ventionaredependentupontheawareness,concern,prudenceandpropertrainingofpersonnelinvolvedintheoperation,transport,maintenanceandstorageofthisequipment.

3. Ithasbeensaid,"Thebestsafetyfeatureisaninformed,carefulopera-tor."Weaskyoutobethatkindofanoperator.Itistheoperator'sresponsibilitytoreadandunder-standALLSafetyandUsinginstructionsinthemanualandtofollowthese.Accidentscanbeavoided.

4. Working with unfamiliar equipment can lead to careless injuries. Read this manual before assembly or using, to acquaint yourself with the machine. If this machine is used by any person other than yourself, or is loaned or rented, it is the machine owner's responsibility to make certain that the operator, prior to using:

a. Reads and understands the operator's manuals.

b. Is instructed in safe and proper use.

5. Knowyourcontrolsandhowtostopengineandmachinequicklyinanemergency.Readthismanualandtheoneprovidedwithyourengine.

6. Trainallnewpersonnelandreviewinstruc-tionsfrequentlywithexistingworkers.Becertainonlyaproperlytrainedandphysicallyablepersonwillusethemachinery.Apersonwhohasnotreadandunderstoodallusingandsafetyinstructionsisnotqualifiedtousethemachine.Anuntrainedoperatorexposeshimselfandbystanderstopossibleseriousin-juryordeath.Iftheelderlyareassistingwiththework,theirphysicallimitationsneedtoberecognizedandaccommodated.

2.4 SAFETy SIGNS

1. Keepsafetysignscleanandlegibleatalltimes.

2. Replacesafetysignsthataremissingorhavebecomeillegible.

3. Replacedpartsthatdisplayedasafetysignshouldalsodisplaythecurrentsign.

4. SafetysignsdisplayedinSection3eachhaveapartnumberinthelowerrighthandcorner.Usethispartnumberwhenorderingreplace-mentparts.

5. Safetysignsareavailablefromyourauthor-izedDistributororDealerPartsDepartmentorthefactory.

How to Install Safety Signs:

• Besurethattheinstallationareaiscleananddry.

• Besuretemperatureisabove50°F(10°C).

• Determineexactpositionbeforeyouremovethebackingpaper.

• Removethesmallestportionofthesplitback-ingpaper.

• Alignthesignoverthespecifiedareaandcarefullypressthesmallportionwiththeex-posedstickybackinginplace.

• Slowlypeelbacktheremainingpaperandcarefullysmooththeremainingportionofthesigninplace.

• Smallairpocketscanbepiercedwithapinandsmoothedoutusingthepieceofsignbackingpaper.

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2.5 PREPARATION

1. Neverusetheengineandmachineuntilyouhavereadandcompletelyunderstandthismanual,theEngineOperator'sManualandeachoftheSafetyMessagesfoundonthesafetysignsontheengineandmachine.

2. Personalpro-tectionequip-mentincludinghardhat,safetyglasses,safetyshoes,andglovesarerec-ommendeddur-ingassembly,installation,operation,adjustment,maintain-ing,repairing,removal,cleaning,ormovingtheunit.Donotallowlonghair,loosefittingclothingorjewellerytobearoundequipment.

3. PROLONGED ExPOSURE TO LOUD NOISE MAy CAUSE PERMANENT HEARING LOSS!

Powerequipmentwithorwithoutequipmentattachedcanoftenbenoisyenoughtocausepermanent,partialhearingloss.Werecommendthatyouwearhearingprotectiononafull-timebasisifthenoiseintheOperator'spositionexceeds80db.Noiseover85dbonalong-termbasiscancauseseverehearingloss.Noiseover90dbadjacenttotheOperatoroveralong-termba-sismaycausepermanent,totalhearingloss.NOTE:Hearinglossfromloudnoise(fromtractors,chainsaws,radios,andothersuchsourcesclosetotheear)iscumulativeoveralifetimewithouthopeofnaturalrecovery.

4. Clearworkingareaofstones,branchesorhiddenobstaclesthatmightbehookedorsnagged,causinginjuryordamage.

5. Useonlyindaylightorgoodartificiallight.

6. Besuremachineisproperlypositioned,ad-justedandingoodoperatingcondition.

7. Ensurethatallsafetyshieldingandsafetysignsareproperlyinstalledandingoodcondi-tion.

2.6 MAINTENANCE SAFETy

1. Goodmaintenanceisyourresponsibility.Poormaintenanceisaninvitationtotrouble.

2. Followgoodshoppractices.

- Keepservice areacleanand dry.

- Besureelectrical outletsandtools areproperly grounded.

- Useadequate lightforthejobat hand.

3. Makesurethereisplentyofventilation.Neveroperatetheen-gineofthetowingvehicleinaclosedbuilding.Theexhaustfumesmaycauseasphyxiation.

4. Beforeworkingonthismachine,shutofftheengineandturnfuelvalveoff.

5. Neverworkunderequipmentunlessitisblockedsecurely.

6. Alwaysusepersonalprotectiondevicessuchaseye,handandhearingprotectors,whenperforminganyserviceormaintenancework.

7. Wherereplacementpartsarenecessaryforperiodicmaintenanceandservicing,genuinefactoryreplacementpartsmustbeusedtorestoreyourequipmenttooriginalspecifica-tions.Themanufacturerwillnotberesponsi-bleforinjuriesordamagescausedbyuseofunapprovedpartsand/oraccessories.

8. Afireextinguisherandfirstaidkitshouldbekeptreadilyaccessiblewhileperformingmain-tenanceonthisequipment.

9. Periodicallytightenallbolts,nutsandscrewsandcheckthatallelectricalandfuelconnectionsareproperlysecuredtoensureunitisinasafecondition.

10.Whencompletingamaintenanceorservicefunction,makesureallsafetyshieldsanddevicesareinstalledbeforeplacingunitinservice.

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2.7 OPERATING SAFETy

1. Readandunderstandoperator'smanualbeforestarting.Reviewsafetyinstructionsannually.

2. Stopanddisableengine, remove ignitionkeyandplaceinyourpocketandwaitforallmov-ingpartstostopbeforeservicing,adjustingorrepairing.

3. To prevent electrical shocks, do not operatethisgeneratorintherainorwithwethands.Itshouldbegroundedindamporhighlyconduc-tiveconditions.

4. Close and secure all guards, deflectors andshieldsbeforestartingandoperating.

5. Donotconnectthegeneratortoacommercialpowerline.

8. Do not operate with damaged or defectiveextensioncords,orpowercords.Neveroper-ateanyelectricalequipmentwithdamagedordefectivecords.

9. Donotoperatethisgeneratorinareaswithpoorventilation.Theexhaustfumescontaincarbonmonoxide,apoisonous,odorless,invisiblegas.Prolongedexposurecanleadtounconscious-nessanddeath.

10.Donotrefueltheenginewhileitisinoperationorstillhot.Donotrefueltheenginenearopenflames,pilotlightsorsparkingelectricaldevices(e.g.powertools,weldersorgrinders).Donotoperatethegeneratornearflammableproducts.

11. Theengineshouldberefueledinawell-litarea.Avoidfuelspillage.

12.Neverallowchildrenorunauthorizedpeopletooperateorbearoundthismachine.

13.Keep theworkingareacleanand freeof de-bristopreventtripping.Operateonlyonlevelground.

14.Donotcoverthegeneratorwhileinoperation.Overheatingcanresultindamagedequipment.

15.Forstorage,donotcoverthegeneratoruntilithascooleddowncompletely.

16.The ambient temperature should not exceed100°F/40°C.

2.8 REFUELING SAFETy

1. Handlefuelwithcare.Itishighlyflammable.

2. Allowenginetocoolfor5minutesbeforerefu-elling.Cleanupspilledfuelbeforerestartingengine.

3. Donotrefuelthemachinewhilesmokingorwhennearopenflameorsparks.

4. Fillfueltankoutdoors.

5. Preventfiresbykeepingmachinecleanofac-cumulatedtrash,greaseanddebris.

2.9 STORAGE SAFETy1. Storetheunitinanareaawayfromhuman

activity.

2. Donotallowchildrentoplayonoraroundthestoredmachine.

3. Storetheunitinadry,levelarea.Supporttheframewithplanksifrequired.

2.10 BATTERy SAFETy1. Keepallsparksandflamesawayfrombatter-

ies,asgasgivenoffbyelectrolyteisexplo-sive.

2. Avoidcontactwithbatteryelectrolyte:washoffanspilledelectrolyteimmediately.

3. Wearsafetyglasseswhenworkingnearbat-teries.

4. Donottipbatteriesmorethan45°,toavoidelectrolyteloss.

5. Toavoidinjuryfromsparkorshortcircuit,dis-connectbatterygroundcablebeforeservicinganypartoftheelectricalsystem.

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2.11 GAS MOTOR SAFETy

BEFORE STARTING ENGINE, READAND UNDERSTAND THE OPERATING AND MAINTENANCE INSTRUCTIONSTHAT CAME WITH yOUR ENGINE.

WARNING: DO NOT

1. DONOTrunengineinanenclosedarea.Ex-haustgasescontaincarbonmonoxide,anodour-lessanddeadlypoison.

2. DONOT place hands or feet nearmoving orrotatingparts.

3. DONOT store, spill, or use gasoline near anopenflame,ordevicessuchasastove,furnace,orwaterheaterwhichuseapilotlightordeviceswhichcancreateaspark.

4. DONOTrefuel indoorswherearea isnotwellventilated.Outdoorrefuellingispreferred.

5. DONOTrefuelwhileengineisrunning.Allowengine tocool for5minutesbefore refuelling.Storefuelinapprovedsafetycontainers.

6. DONOTremovefueltankcapwhileengineisrunning.

7. DONOToperateengine if gasoline is spilled.Movemachineawayfromthespillandavoidcre-atinganyignitionuntilgasolinehasevaporated.

8. DONOTsmokewhilefillingfueltank.

9. DONOTchokecarburetortostopengine.When-ever possible, gradually reduce engine speedbeforestopping.

10.DONOTrunengineaboveratedspeeds.Thismayresultininjury.

11. DONOTtamperwithgovernorsprings,gover-norlinksorotherpartswhichmayincreasethegovernedspeed.

12.DONOTtamperwiththeenginespeedselectedbytheoriginalequipmentmanufacturer.

13.DONOTcheckforsparkwithsparkplugorsparkplugwireremoved.

14.DONOTcrankenginewithsparkplugremoved.Ifengineisflooded,crankuntilenginestarts.

15.DO NOT strike flywheel with a hard object ormetaltoolasthismaycauseflywheeltoshatterinoperation.Usepropertoolstoserviceengine.

16.DONOToperateenginewithoutamuffler.Inspectperiodicallyandreplace,ifnecessary.Ifengineisequippedwithamufflerdeflector,inspectpe-riodicallyand replace, ifnecessarywithcorrectdeflector.

17.DONOToperateenginewithanaccumulationofgrass,leaves,dirtorothercombustiblematerialsinthemufflerarea.

18.DONOTusethisengineonanyforestcovered,brushcovered,orgrasscoveredunimprovedlandunlessasparkarresterisinstalledonthemuffler.Thearrestermustbemaintainedineffectivework-ingorderbytheoperator.InthestateofCaliforniatheaboveisrequiredbylaw(Section4442oftheCaliforniaPublicResourcesCode).Otherstatesmayhavesimilar laws. Federal lawsapplyonfederalland.

19.DONOT touchhotmuffler, cylinderor finsbe-causecontactmaycauseburns.

20.DONOTrunenginewithaircleaneroraircleanercoverremoved.

WARNING: DO

1. ALWAYSDOremovethewirefromthesparkplugwhenservicingtheengineorequipmenttopre-ventaccidentalstarting.Disconnectthenegativewirefromthebatteryterminalifequippedwita12voltstartingsystem.

2. DOkeepcylinderfinsandgovernorpartsfreeofgrassandotherdebriswhichcanaffectenginespeed.

3. DOexaminemufflerperiodicallytobesureit isfunctioningeffectively.Awornorleakingmufflershouldberepairedorreplacedasnecessary.

4. DOusefreshgasoline.Stalefuelcangumcar-buretorandcauseleakage.

5. DO check fuel lines and fittings frequently forcracksorleaks.Replaceifnecessary.

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2.12 SIGN-OFF FORMSurgeMasterfollowsthegeneralSafetyStandardsspecifiedbytheAmericanSocietyofAgriculturalandBiologicalEngineers(ASABE)andtheOccupationalSafetyandHealthAdministration(OSHA).Anyonewhowillbeusingand/ormaintainingthePortableGeneratormustreadandclearlyunderstandALLSafety,UsageandMaintenanceinformationpresentedinthismanual.

Donotuseorallowanyoneelsetousethisgeneratoruntilsuchinformationhasbeenreviewed.Annuallyreviewthisinformationbeforetheseasonstart-up.

MaketheseperiodicreviewsofSAFETYandOPERATIONastandardpracticeforallofyourequipment.Wefeelthatanuntrainedoperatorisunqualifiedtousethismachine.

Asign-offsheetisprovidedforyourrecordkeepingtoshowthatallpersonnelwhowillbeworkingwiththeequipmenthavereadandunderstandtheinformationintheOperator’sManualandhavebeeninstructedintheoperationoftheequipment.

EMPLOyEES SIGNATURE EMPLOyERS SIGNATURE

SIGN-OFF FORM

DATE

15

REMEMBER-Ifsafetysignshavebeendamaged,removed,becomeillegibleorpartsreplacedwithoutsafetysigns,newsignsmustbeapplied.Newsafetysignsareavailablefromyourauthorizeddealer.

3 SAFETy SIGN LOCATIONS Thetypesofsafetysignsandlocationsontheequipmentareshownintheillustrationsthatfollow.Goodsafetyrequiresthatyoufamiliarizeyourselfwiththevarioussafetysigns,thetypeofwarningandthearea,orparticularfunctionrelatedtothatarea,thatrequiresyourSAFETYAWARENESS.

•ThinkSAFETY!WorkSAFELY!

A

• 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.

• To prevent electrical shocks, do not operate this genera-tor in the rain or with wet hands. It should be grounded in damp or highly conductive conditions.

• Close and secure all guards, deflectors and shields before starting and operating.

• Do not connect the generator to a commercial power line.

• Do not operate with damaged or defective extension cords, or power cords. Never operate any electrical equipment with damaged or defective cords.

• Do not operate this generator in areas with poor ventila-tion. The exhaust fumes contain carbon monoxide, a poisonous, odorless, invisible gas. Prolonged exposure can lead to unconsciousness and death.

• Do not refuel the engine while it is in operation or still hot. Do not refuel the engine near open flames, pilot lights or sparking electrical devices (e.g. power tools, welders or grinders). Do not operate the generator near flammable 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 debris to prevent tripping. Operate only on level ground.

• Do not cover the generator while in operation. Overheat-ing 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.

SM11000E

B

Z94216

Do not operate this generator in areas with poor ventila-tion. The exhaust

fumes contain carbon monoxide, a poisonous, odor-less, invisible gas.

Prolonged exposure can lead to uncon-

sciousness and death.

C

C

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4 ASSEMBLING Themachinecomesfromthefactoryinashippingcrateandconfiguration.Alwaysusetoolsequipmentandforkliftsofappropriatesizeandcapacityforthejob. Alwaysuse2menwhen lifting,movingandassemblingthemachine.

Whenthemachineisshipped,followthisprocedurewhenpreparingforthecustomer:

1. Clear theareaofbystandersespeciallysmallchildrenbeforestarting.

2. Movethemachinetotheassemblyarea.Besurethereissufficientclearancetoaccessthemachinefromallsides.

3. Removethelidandlaytotheside.

4. Useahoistoracranetolifttheunitoutofitscrate.

TyPICAL CRATING

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4.1 INSTALL BATTERy:1. Removecables,clampsandbrackets

fromtheirshippingposition.2. Bringabatterytothemachine.3. Layoutcomponents.4. Positionbatteryinitstray.5. Installthethreaded"J"hooksintothebat-

terytray.

36Ahbatteryisrecommended

6. Installtheholddownstrapontothe"J"hooksoverthebattery.

7. Treadonthewingnuts,snuguptightly.8. Attachcablefromthestartersolonoid

topositive(+)batterypostandtightensucurely.

9. Attachthecablefromthegroundpostonthestartertothenegative(-)postonthebattery(neutralisbondedtotheframe)

Caution: Poison/Danger-CausesSevereBurns.Thebatterycontains

sulphuric acid.Avoid contactwith skin,eyes or clothing. Keep out of reach ofchildren.

BATTERYSAFETY

1. Wearglovesandsafetyglassesorfaceshieldwhenworkingonornearbatteries.

2. Useabatterycarriertoliftthebatteryorplacehandsatoppositecornerstoavoidspillingacidthroughthevents.

3. Avoidcontactwithbatteryelectrolyte:External Contact: Flushimmediatelywithwater. Eye Contact:Flushwithwaterfor15minutes.Getpromptmedicalattention.Cleanupanyspilledelectrolyteimmediately.

4. Avoidcontactwithbatteryposts,terminalsandrelatedaccessories,theycontainleadandleadcompounds,chemicalsknowntocauseharm.Washhandsimmediatelyafterhandlingbattery.

5. Keepallsparksandflamesawayfrombatter-ies,asgasgivenoffbyelectrolyteisexplo-sive.

6. Toavoidinjuryfromsparkorshortcircuit,dis-connectbatterygroundcablebeforeservicinganypartoftheelectricalsystem.

7. FROZENBATTERIESCANEXPLODEandresultindeathorseriousinjury.DONOTjumpstart/chargeafrozenbattery.Letbatterythawbeforecharging.

StarterGroundPost(-)

StarterSolenoid(+)

WingNut

HoldDownStrap

BatteryCable

"J"Hook

18

5 OPERATION

TheSurgeMasterPortableGeneratorsarede-signedtoprovideportableelectricalpowertoequipmentthatisnotconnectedtotheelectricalgridsystem.

It is the responsibility of the owner or opera-tor to read this manual and to train all other operators before they start working with the machine. Follow all safety instructions exact-ly. Safety is everyone's business. By follow-ing recommended procedures, a safe working environment is provided for the operator, bystanders and the area around the work site. Untrained operators are not qualified to use the machine.

Manyfeaturesincorporatedintothismachinearetheresultofsuggestionsmadebycustomerslikeyou.ReadthismanualcarefullytolearnhowtousetheGeneratorsafelyandhowtosetittoprovidemaximumfieldefficiency.Byfollowingtheusinginstructionsinconjunctionwithagoodmaintenanceprogram,yourPortableGeneratorwillprovidemanyyearsoftrouble-freeservice.

5.1 TO THE NEW OPERATOR OR OWNER

OPERATING SAFETy• Readandunderstandoperator'smanualbefore

starting.Reviewsafetyinstructionsannually.

• Stopanddisableengine,removeignitionkeyandplaceinyourpocketandwaitforallmov-ingpartstostopbeforeservicing,adjustingorrepairing.

• To prevent electrical shocks, do not operatethisgeneratorintherainorwithwethands.Itshouldbegroundedindamporhighlyconduc-tiveconditions.

• Close and secure all guards, deflectors andshieldsbeforestartingandoperating.

• Donotconnectthegeneratortoacommercialpowerline.

• Do not operate with damaged or defectiveextensioncords,orpowercords.Neveroper-ateanyelectricalequipmentwithdamagedordefectivecords.

• Donotoperatethisgeneratorinareaswithpoorventilation.Theexhaustfumescontaincarbonmonoxide,apoisonous,odorless,invisiblegas.Prolongedexposurecanleadtounconscious-nessanddeath.

• Donotrefueltheenginewhileitisinoperationorstillhot.Donotrefueltheenginenearopenflames,pilotlightsorsparkingelectricaldevices(e.g.powertools,weldersorgrinders).Donotoperatethegeneratornearflammableproducts.

• Theengineshouldberefuelledinawell-litarea.Avoidfuelspillage.

• Neverallowchildrenorunauthorizedpeopletooperateorbearoundthismachine.

• Keeptheworkingareacleanandfreeofde-bristopreventtripping.Operateonlyonlevelground.

• Donotcoverthegeneratorwhileinoperation.Overheatingcanresultindamagedequipment.

• Forstorage,donotcoverthegeneratoruntilithascooleddowncompletely.

• Theambienttemperatureshouldnotexceed100°F/40°C.

19

5.2 MACHINE COMPONENTSThe Su r g eMas t e r SM11000LHE Po r t -able Generator consists of a 20 hp Hon-da engine driving a 11,000 watt electricalgenera tor. A l l cont ro l and power out -lets are mounted on the front of the frame forconvenientaccessandoperation.

Theunitisdesignedtoprovide120Vor240V60Hzpowerasabackuppowersupplyataremotelocation.Eachoutletisdesignedwithacircuitbreakertoprotectagainstoverload.Themachineisneutralbondedtotheframe.Thebatteryandfueltankaremountedintheframeforconvenientaccess.

HOURS 1/10

HondaGX630Engine

12kVaAlternator

ElectricalControlPanel

Battery(notincluded,

36Ahrecommended)

FuelTank

LiftEye

20AmpBreakers

120/240vOutlets120vOutlets

MainSwitch

HourMeter

OilAlert

Choke

HondaGX630ControlPanel

Ignition

Note:checktheHondaGX630ownersmanualfordetailedengineinformation.

FuelShut-off

RearView

30AmpBreakers

20

5.3 MACHINE BREAK-INAlthoughtherearenooperationalrestrictionsonthePortableGeneratorwhenusedforthefirsttime,itisrecommendedthatthefollowingmechanicalitemsbechecked:

A. After operating for 1 hour:

1. Re-torqueallfastenersandhardware.

2. Check condition of all electrical connec-tions.

3. Checkfluidlevels.Topupasrequired.

B. After operating for 10 hours:

1. Repeatsteps1through3listedabove. (SectionA)

2. Changeengineoil.

3. Go to the normal servicing and mainte-nancescheduleasdefinedintheMainte-nanceSection.

5.4 PRE-OPERATION CHECKLIST

Efficient and safe operation of the SurgeMasterPortable Generator requires that each operatorreadsandunderstandstheusingproceduresandall relatedsafetyprecautionsoutlined in thissec-tion. Apre-operationchecklist isprovidedfor theoperator.Itisimportantforboththepersonalsafetyandmaintaininggoodmechanicalconditionthatthischecklistisfollowed.

BeforeoperatingPortableGeneratorandeachtimethereafter, thefollowingareasshouldbecheckedoff:

1. Checkenginefluidlevels.Topupasrequired.

2. Checkallelectricalconnections.Replace,re-pairorcleanasrequired.

3. Make sure that all guards and shields are inplace,securedandfunctioningasdesigned.

21

5.5 CONTROLS

Beforestartingtowork,alloperatorsshouldfamil-iarizethemselveswiththelocationandfunctionofcontrols.Thisappliestoallmodels.

5.51 ENGINE: Readtheenginemanufacturersoperator's

manualbeforestartingformoredetailedinstructions.

Ignition Switch: Thiskeyoperatedswitchcontrolstheelectric

powertotheengine.

OFF- Turnkeyfullycounterclockwisetostoptheelectricalsystempowerandturntheengineoff.

ON-Turnclockwiseondetenttotherunposition.Thisisthepositionwheretheenginewillcontinuetorun.

START-Turnfullyclockwisetothelastspring-loadeddetentpositiontoengagethestartersolenoidandstarttheengine.ReleasethekeywhentheenginestartsanditwillreturntotheRUNposition.

Choke: Thispush/pullknobcontrolsthepositionof

thechoke.Pulltheknobouttoclosethechokeforstartingwhentheengineiscold.Pushtheknobintoopenthechokeastheenginewarms.Alwayspushtheknobfullyinwhenoperatingthemachine.

Oil Alert: TheOilAlertsystemisdesignedtoprevent

enginedamagecausedbyaninsufficientamountofoilinthecrankcase.Beforetheoillevelinthecrankcasecanfallbelowasafelimit,theOil Alertindicator(red)comesonandtheOilAlertsystemwillauto-maticallystoptheengine(theengineswitchwillremainintheONposition).

Hour Meter:Afterstartingtheengine,theelapsedtimeoftheengineinusewillbecounted.Itwillnotcounttheelapsedtimeoftheengineopera-tionbyjustturningtheengineswitchON.

HOURS 1/10

HourMeter

OilAlert

Choke

HondaGX630ControlPanel

Ignition

22

5.52 ELECTRICAL CONTROLS:SM11000LHE

IMPORTANTAcircuitbreakerthattripsrepeatedlymayindicateaproblem.

SM11000LHE

A

B C D

E F

G

H

A. Thesetwooutlets(5-20R)areusedtoprovide120Volt,20Amppower.

B. Thisoutlet(L5-30)isusedtoprovide120Volt,30Amppower.

C. Thisoutlet(L14-30)isusedtoprovide120/240Volt,30Amppower.

D. Thisoutlet(14-50R)isusedtoprovide120/240Volt,50Amppower.

E. These20Ampbreakersareusedtoprotectthe20Amp120Voltoutlets(A).Pushtheswitchtoreset.

F. These30Ampcircuitbreakersprotectsthetwo30Ampoutlets.(B&C).Pushtheswitchtoreset.

G. Main Switch / 50Amp breaker is themasteroverloadforthegenerator.Movetheswitchuptoengageanddowntodisengagethebreaker.

23

5.6 FIELD OPERATION

AlthoughthePortableGeneratoriseasytouse,eachoperator should review this section to familiarizehimself with the detailed safety and operatingprocedures.Whenusingthismachine,followthisprocedure:

1. Cleartheareaofbystanders,especiallysmallchildren.

2. ReviewandfollowthePre-OperationChecklist(seeSection5.4).

OPERATING SAFETy• Readandunderstandoperator'smanualbefore

starting.Reviewsafetyinstructionsannually.

• Stopanddisableengine,removeignitionkeyandplaceinyourpocketandwaitforallmov-ingpartstostopbeforeservicing,adjustingorrepairing.

• To prevent electrical shocks, do not operatethisgeneratorintherainorwithwethands.Itshouldbegroundedindamporhighlyconduc-tiveconditions.

• Close and secure all guards, deflectors andshieldsbeforestartingandoperating.

• Donotconnectthegeneratortoacommercialpowerline.

• Do not operate with damaged or defectiveextensioncords,orpowercords.Neveroper-ateanyelectricalequipmentwithdamagedordefectivecords.

• Donotoperatethisgeneratorinareaswithpoorventilation.Theexhaustfumescontaincarbonmonoxide,apoisonous,odorless,invisiblegas.Prolongedexposurecanleadtounconscious-nessanddeath.

• Donotrefueltheenginewhileitisinoperationorstillhot.Donotrefueltheenginenearopenflames,pilotlightsorsparkingelectricaldevices(e.g.powertools,weldersorgrinders).Donotoperatethegeneratornearflammableproducts.

• Theengineshouldberefuelledinawell-litarea.Avoidfuelspillage.

• Neverallowchildrenorunauthorizedpeopletooperateorbearoundthismachine.

• Keeptheworkingareacleanandfreeofde-bristopreventtripping.Operateonlyonlevelground.

• Donotcoverthegeneratorwhileinoperation.Overheatingcanresultindamagedequipment.

• Forstorage,donotcoverthegeneratoruntilithascooleddowncompletely.

• Theambienttemperatureshouldnotexceed100°F/40°C.

3. Positionthegeneratorinthefollowingmanner:

a. Leveltominimizethechanceofspillingfuel.

b. Inadryareatopreventshocksandshorts.

c. Awayfromallflammableliquidsandfumes.

d. Withaground tominimize thechanceofshocksandshorts.

24

4. Starting the Generator:

a. Plug in power cords from appliances orloads.

b. Turnall theappliancesorelectrical loadsoff.

c. Refertoenginemanualfordetailedenginestartingprocedure.

d. Usetheignitionkeytoengagethestarter.

e. Pullout thechoke if theengine iscoldorhasn'tbeenrunforawhile.

f. Runtheengineuntilitwarmsandthechokeiscompletelyclosed.

g. Turntheapplianceonorplugintheelectri-calload.

SM11000LHE

5. Stopping:

a. Turntheapplianceofforunplugtheelectri-calload.

b. Run the engine for approximately threeminutestoallowtheenginetocool.

c. Turnengineoff.

6. Emergency Stopping:

• Immediatelyswitchoffthemainbreaker• Turntheengineoff.

Correcttheconditionbeforeresumingworkandre-startingtheengine.

7. Terrain:

Thegeneratorworkswell inawidevarietyofoperating conditions but it should always bepositioned on the level. When the frame islevel,fuelspillageisminimizedandthegastankcapacityismaximized.Donotoperateunlesstheframeislevel.

25

8. Weather:

a. Donotoperateintherainorwithwethands.Keep thegeneratorandworkareadry topreventshocksandshorts.Alwaysgroundtheframewhenoperating indamporwetconditions.

b. Do not operate at temperatures above100° F (40°C) to prevent overheating ofthe engine or generator. Always run forapproximately three minutes without anelectricalloadtocoolthecomponentsbe-foreshutdown.

9. Electrical Loads:

Thegeneratorisideallysuitedtocamping,boat-ing, farm, household, workshop, constructionsiteoranywherethatback-uppowerisrequired.Inordertodeterminethepowerrequirementsofyourappliance,refertoTable1.Thereareapproximationsonly.Ifthepowerdrawfortheapplianceexceedstheoutletcapacity,thecir-cuitbreakerwillbetripped.Reducethecurrentdraw and reset the breaker before resumingoperation.

Generator Usage Start Watts Running Watts LHE11000LHE Refrigerator, Freezer 2500 700 Y Toaster 1050 Y Microwave 950 Y Coffee Maker 1500 850 Y Washing Machine 2000 750 Y Furnace Fan 1400 700 Y Sump Pump 2500 600 Y TV 350 Y Circular Saw 1500 750 Y Drill 1000 250 Y Sander 1000 375 YY=WILLOPERATE PLEASENOTETHATTHISTABLEREPRESENTSASAMPLEOFAPPLICATIONSONLY TABLE 1

10. Electrical Component Condition:

Alwaysuseelectrical components thatare ingood condition. Do not use electrical cords,plugsandconnectorsthatarefrayed,damaged,cracked or not in good condition. Electricalcomponentsthatarenotingoodconditioncanleadtoshocks,shortsorsparking.Anyoftheseconditionscancreateandleadtoanundesir-ableorunsafesituation.

26

11. Electrical Hazards: Thegeneratorisdesignedtogeneratean

electricalcurrentatahighenoughpowerleveltogetmeaningfulworkdone.However,powerattheselevelsalsoincludesthepos-sibilityofelectricalhazards.Somethingstorememberaboutelectricalhazardsincludebutarenotlimitedto:

a. Keepallelectricalcomponentsingoodcondition.

b. Donotoperatewithfrayed,crackedordamagedparts.

c. Groundtheframeifoperatingindamporwetconditions.

d. Donotoperatewithwethands.

IMPORTANTAcircuitbreakerthattripsrepeatedlymayindicateaproblem.

SM11000LHE

12. Circuit Breakers: Eachofoutletsontheelectricalpanelispro-

tectedwithacircuitbreakertopreventover-loadingthecircuit.Ifabreakertrips,reducetheloadbeforere-settingthebreaker.

• Thetwo120volt20ampGFCI(5-20R)outletsareeachprotectedbya20amppopupcircuitbreaker.

• The120volt30amp(L5-30)andthe120/240volt30amp(L14-30)receptaclesareeachprotectedbya30amppopupbreaker.Ifthisbreakertripsthenthe30ampcircuitwillbeoff.

• The120/240volt50amp(6-50R&14-50R)receptaclesareprotectedbya50ampbreaker,whichalsoservesasthemainoff/onswitch.Ifthisbreakertripsallthecircuitswillbeoff.

50Amp

30Amp

20Amp

27

14. Operating Hints:

a. Positionframeonalevelareatominimizethechanceofspillingfuelandmaximizethefuelcapacityofthetank.Spilledfuelcanbeignitedbyasparkfromtheelectricalpowersystem.

b. Donotrefuelwhiletheengineisrunning.Waituntiltheunithascooledbeforerefuelling.

c. Keeptheworkingareaneatandcleantopre-ventslippingandtripping.Preventaccidentsattheworksite.

d. Always ground the frame to minimize thechanceofsparks,shocksorshorts.Thisisveryimportant indamp,wetorrainycondi-tions.

e. Positionthegeneratorundercovertoprotectitfromrainorbadweather.

f. Donotoperatewhentheambienttempera-tureexceeds100°F(39°C)topreventover-heating.

g. Do not cover the unit during operation topreventoverheating.

Clean and dry: good operating conditions

28

Thegeneratorisdesignedtobeeasilymovedfromonelocationtoanother.Reviewthefollowingdetailsonhowtheunitcanbemoved:

1. Lift Eye: Theframeisdesignedwithalifteyethatpro-

videsanattachpointformovingwithan"A"frame,forklift,craneorotherliftingsystem.

2. Wheel Kit: TheSM1000LHEstandardfeatureincludesa

wheelkittomakemovementaroundtheworkareaeasierandsafer.Kitconsistsofafolddownhandleand13"pneumatictiresmount-edonanaxle.

3. Transporting: Whentransportingfromlocationtolocation,

followthisprocedure:

a. Runtheengine(usethegenerator)until thefueltankisemptyornearlyempty.

b. Turnthefuellineoff.

5.7 MOVING

LiftEye

FuelLineShut-off

Folddownhandle

29

OPERATING SAFETy• Store theunit inanareaaway fromhuman

activity.

• Donotpermitchildren toplayonoraroundthestoredmachine.

• Storetheunitinadry,levelarea.Supporttheframewithplanksifrequired.

5.8 STORAGE

Aftertheseason'suseorwhenthemachinewillnotbeusedforaperiodoftime,completelyinspectallmajorsystemsofthePortableGenerator.Replaceorrepairanywornordamagedcomponentstopre-ventanyunnecessarydowntimeatthebeginningofthenextseason.

Followthisprocedurebeforestoring:

1. Removeallplugsorelectrical loads from theelectricalpanel.

2. Thoroughlycleanthemachinewithadampclothtoremovealldirt,mudordebris.

3. Inspectallrotatingpartsforentangledmaterial.Removeallentangledmaterial.

4. Turnfuelvalveoff.

5. Touchupallpaintnicksandscratchestopreventrusting.

6. Removeignitionkeyandstoreinasecureplace.

7. Removethebatteryandstoreitinacool,dryarea on wooden blocks or a wooden pallet.Charge it monthly to maintain an adequatecharge.

8. Itisbesttostorethemachineinside.Ifthatisnotpossible,coverwithawaterprooftarpaulinandtiedownsecurely.

9. Storeinanareaawayfromhumanactivity.

10.Donotallowchildrentoplayaroundthestoredunit.

Whenremovingthismachinefromstorage,follow

5.8.1 PLACING IN STORAGE

thisprocedure:

1. Removethetarpaulinifcovered.

2. Installandconnectthebattery.

3. Bringtheignitionkey.

4. Reviewandfollowthepre-operationchecklist.

5.8.2 REMOVING FROM STORAGE

IMPORTANT

Ifthemachinehasbeenstoredformorethan6months,warmtheenginebyrunningitfor2-3minutesanddraintheoil.Changetheoilwhiletheoiliswarmtoremoveanycondensation.RefertoMaintenancesection.

STORED (Typical)

30

MAINTENANCE SAFETy

• Good maintenance is your responsibility.Poormaintenanceisaninvitationtotrouble.

• Followgoodshoppractices.

- Keepserviceareacleananddry. - Besureelectricaloutletsandtoolsare properlygrounded. - Useadequatelightforthejobathand.

• Makesurethereisplentyofventilation.Nev-eroperatetheengineofthetowingvehicleinaclosedbuilding. Theexhaust fumesmaycauseasphyxiation.

• Beforeworkingonthismachine,shutofftheengine,setthebrake,andturnfuelvalveoff.

• Neverworkunderequipmentunlessitisblockedsecurely.

• Alwaysusepersonalprotectiondevicessuchaseye,handandhearingprotectors,whenperforminganyserviceormain-tenancework.Useheavygloveswhenhandlingsharpcomponents.

• Wherereplacementpartsarenecessaryforperiodicmaintenanceandservicing,genuinefactoryreplacementpartsmustbeusedtorestoreyourequipmenttooriginalspecifications.Themanufacturerwillnotberesponsibleforinjuriesordamagescausedbyuseofunapprovedpartsand/oracces-sories.

• Afireextinguisherandfirstaidkitshouldbekeptreadilyaccessiblewhileperformingmaintenanceonthisequipment.

• Periodicallytightenallbolts,nutsandscrewsandcheckthatallelectricalandfuelconnectionsareproperlysecuredtoensureunitisinasafecondition.

• Whencompletingamaintenanceor servicefunction,makesureallsafetyshieldsandde-vicesareinstalledbeforeplacingunitinserv-ice.

6 SERVICE AND MAINTENANCE6.1 SERVICE

6.1.1 FLUIDS AND LUBRICANTS

1. Grease: UseanSAEmultipurposehightemperature

greasewithextremepressure(EP)perform-ance.AlsoacceptableisanSAEmultipur-poselithiumbasegrease.

2. Engine Oil: SeeHondaengineownersmanualforfullde-

tailonoiltypespecifictooperatingconditionsandcapacity.

3. Engine Gasoline: SeeHondaengineownersmanualforfull

detailonfueltypesandlimitations.

FuelTankCapacity:40Liter,(10.5USgal)

4. Storing Lubricants: Yourmachinecanoperateattopefficiency

onlyifcleanlubricantsareused.Usecleancontainerstohandlealllubricants.Storetheminanareaprotectedfromdust,moistureandothercontaminants.

6.1.2 FLUIDS AND LUBRICANTS

UsetheMaintenanceChecklistprovidedtokeeparecordofallscheduledmaintenance.

1. Useahand-heldgreasegunforallgreasing.

2. Wipegreasefittingwithacleanclothbeforegreasing,toavoidinjectingdirtandgrit.

3. Replaceandrepairbrokenfittingsimmedi-ately.

4. Iffittingswillnottakegrease,removeandcleanthoroughly.Alsocleanlubricantpas-sageway.Replacefittingsifnecessary.

31

6.1.3 SERVICE RECORD

SeeLubricationandMaintenancesectionsfordetailsofservice.Copythispagetocontinuerecord.

ACTIONCODE CK CHECK CL CLEAN RREPLACE CH CHANGE HOURS

SERVICED By MAINTENANCE

8 Hours or Daily CK EngineOilLevel CK FuelLevel

40 Hours or Weekly CL AirCleaner

100 Hours or Monthly CH EngineOil CH EngineOilFilter R FuelFilter R AirCleaner Annually CL Machine

6.2 MAINTENANCEByfollowingacarefulserviceandmaintenanceprogramforyourmachine,youwillenjoymanyyearsof

trouble-freeoperation.

Putthemachineinsafeconditionbeforeworkingonthismachine,•shutofftheengine.•ensureallcomponentshavestoppedmoving.•removeandpockettheignitionkey.•disconnectthebattery.•block&chockthewheels.

HondaGX630EngineForperiodicservice,reviewyourenginesinstructionmanualforspecificinstructions/requirementsfor:•Oil•Oilfilter•Aircleaner•Fuelfilter•Fuellines

DANGERDo not smoke when working on fuel system. Keep all sparks, flames or hot materials away from machine.

32

Enginedoesn'tstart. Nofuel. Fillfueltank.

Fuelfilterplugged. Replacefuelfilter.

Weakbattery. Rechargeorreplacebattery.

Loadedelectrically. Removeelectricload.

Breakerstripping. Electricalloadtoohigh. Reduceelectricalload.

7 TROUBLE SHOOTINGTheSurgeMasterPortableGeneratorisdesignedtogenerateupto10,000continuouswattsofpoweratanytypeofremotelocation.Itisasimpleandreliablesystemthatrequiresminimalmaintenance.

Inthefollowingsection,wehavelistedmanyoftheproblems,causesandsolutionstotheproblemsthatyoumayencounter.

Ifyouencounteraproblemthatisdifficulttosolve,evenafterhavingreadthroughthistroubleshootingsection,pleasecallyourlocaldistributorordealer.Beforeyoucall,pleasehavethisOperator'sManualfromyourunitandserialnumberready.

PROBLEM CAUSE SOLUTION

33

8 SPECIFICATIONS8.1 MECHANICAL

SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE

SM11000HLHE

Engine 20hp/GX630

Maximum Watts 12,000

Continuous Watts 10,000

Maximum Amps 100/50 120 V / 240 V

Continuous Amps 84/42

Frequency 60Hz

Voltage 120/240

Fuel Tank Capacity 40litres

Run Time 1/2 Load 10hours Full Load 7hours

Weight 348lbs

Dimensions 32"Lx22"Wx 29"H

Overload Protection Yes

Engine Starting Electric

Hour Meter Yes

GFI Receptacles No

34

8.2 BOLT TORQUE

CHECKING BOLT TORQUE

Thetablesshownbelowgivecorrecttorquevaluesforvariousboltsandcapscrews.Tightenallboltstothetorquesspecifiedinchartunlessotherwisenoted.Checktightnessofboltsperiodically,usingbolttorquechartasaguide.Replacehardwarewiththesamestrengthbolt.

ENGLISH TORQUE SPECIFICATIONS

METRIC TORQUE SPECIFICATIONS

SAE 2(N.m) (lb-ft)

Bolt Torque*Bolt

Diameter"A"

SAE 5(N.m) (lb-ft)

SAE 8(N.m) (lb-ft)

1/4"5/16"3/8"7/16"1/2"9/16"5/8"3/4"7/8"1"

81327416195128225230345

6102030456095165170225

12254572110155215390570850

919335380115160290420630

1736631001552203055408801320

12274575115165220400650970

8.8(N.m) (lb-ft)

Bolt Torque*Bolt

Diameter"A"

10.9(N.m) (lb-ft)

M3M4M5M6M8M10M12M14M16M20M24M30M36

.5361025509014022543575014952600

.42.24718376610316632155311031917

1.84.59153570125200310610105021003675

1.33.371126529214822945077415502710

Torquefiguresindicatedabovearevalidfornon-greasedornon-oiledthreadsandheadsunlessoth-erwisespecified.Therefore,donotgreaseoroilboltsorcapscrewsunlessotherwisespecifiedinthismanual.Whenusinglockingelements,increasetorquevaluesby5%.

*Torquevalueforboltsandcapscrewsareidentifiedbytheirheadmarkings.

35

INDExSymbols12 KVA ALTERNATOR ......................................1920 AMP ...............................................................2730 AMP ...............................................................2750 AMP ...............................................................27AASABE ...............................................................14BBATTERy ...........................................................17CCAUTION .............................................................7CHOKE ...............................................................21CIRCUIT BREAKERS ........................................27COMPONENT CONDITION ...............................26DDANGER ..............................................................7EELECTRICAL LOADS .......................................26EMERGENCy ....................................................25ENGINE OIL .......................................................31ENGINE SERIAL NUMBER .................................5GGENERATOR SERIAL NUMBER ........................5GFCI ...................................................................23GREASE ............................................................31Gx630 ................................................................32HHAZARDS ..........................................................27HOUR METER ............................................ 19, 21HOW TO INSTALL SAFETy SIGNS ..................10IIGNITION SWITCH ............................................21L

LIFT EyE ..................................................... 19, 29LOUD NOISE ..................................................... 11LUBRICANTS ....................................................31MMAIN SWITCH ...................................................19MODEL NUMBER ................................................5OOFF ....................................................................21OIL ALERT .........................................................21OIL USE HOURS METER ..................................19ON ......................................................................21OPERATING HINTS ...........................................28OPERATOR ORIENTATION ................................6PPROTECTIVE GEAR ...........................................8SSAFETy ...............................................................8SIGNAL WORDS .................................................7START ................................................................21STARTING .........................................................25STOPPING .........................................................25TTERRAIN ............................................................25TRANSPORTING ...............................................29VVOLT METER .....................................................19WWARNING ............................................................7WARNING: DO ...................................................13WARNING: DO NOT ..........................................13WEATHER ..........................................................26WHEEL KIT ........................................................29