Surge master SHS3000R, SCS3000, SCS5000, SCS3000R, SCS5000R Operator's Manual

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BY EMB MFG INC.

EMB Manufacturing Inc.

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

Ph: (519) 699-9283 · Fax: (519) 699-4146

www.surgemaster.ca

STANDARD PORTABLE

GENERATORS

OPERATOR'S MANUAL

SHS3000

SHS3000R

SCS3000

SCS3000R

SHS7000

SHS7000R

SCS7000

SCS7000R

SHS3000

SHS3000R

SHS5000

SHS5000R

SHS7000

SHS7000R

FIRST USE: DO NOT attempt to crank or start the engine

before it has been properly lled with the recommended amount and type of oil.

Damage to the generator as a result of failure to follow these instructions will void your

warranty. See the engine owners manual for detailed instructions.

SCS3000

SCS3000R

SCS5000

SCS5000R

SCS7000

SCS7000R

SHS5000

SHS5000R

SCS5000

SCS5000R

Thoroughly review this manual and the engine manual for

U1 Lawn & Garden 250 CCA battery is not included

Keep this manual with the Generator at all times

PRINTED IN CANADA REV 080316 PART NUMBER: Z97094

safe and proper operation.

ELECTRICAL SAFETY

CERTIFIED.

TABLE OF CONTENTS

WARRANTY ............................................................... 3

DELIVERY INSPECTION REPORT ........................... 4

SERIAL NUMBER LOCATION .................................. 5

LABEL INFORMATION ............................................. 5

1 INTRODUCTION ........................................... 6

2 SAFETY ........................................................ 7

2.1 SAFETY DO'S & DON'TS' ......................... 8

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

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

2.4 PREPARATION ........................................ 10

2.5 MAINTENANCE SAFETY .........................11

2.6 BATTERY SAFETY ...................................11

2.7 REFUELING SAFETY ............................. 12

2.8 OPERATING SAFETY ............................. 12

2.9 TRANSPORT SAFETY ............................ 13

2.10 STORAGE SAFETY................................. 13

2.11 ELECTRICAL SAFETY ............................ 13

2.12 GAS MOTOR SAFETY ............................ 14

2.13 SIGN-OFF FORM .................................... 15

3 SAFETY SIGNS .......................................... 16

3.1 HOW TO INSTALL SAFETY SIGNS: ....... 16

3.2 SAFETY SIGN EXPLANATIONS: ............ 16

4 OPERATION & FEATURES ....................... 18

4.1 TO THE NEW OPERATOR OR OWNER 18

4.1.1 SAFE CONDITION ................................. 18

4.2 MACHINE COMPONENTS ...................... 19

4.3 MACHINE BREAK-IN .............................. 20

4.4 PREOPERATION CHECKLIST................ 20

4.5 CONTROLS ............................................. 21

4.5.1 ENGINE CONTROLS .............................. 21

4.5.2 ELECTRICAL PANEL FEATURES ........... 22

4.5.3 ELECTRICAL PANEL............................... 23

SHS3000 & SHS3000R ....................... 23

SCS3000 & SCS3000R ....................... 23

SHS5000 & SHS5000R ....................... 23

SCS5000 & SCS5000R ....................... 24

SHS7000 & SHS7000R ....................... 24

SCS7000 & SCS7000R ....................... 24

CIRCUIT BREAKERS:......................... 25

OPERATING HINTS: ........................... 25

4.6 ELECTRICAL LOAD ...........................26

4.6.1 WATTAGE AND LOAD .........................26

REACTIVE LOAD ............................26

RESISTIVE LOAD ...........................26

CONTINUOUS WATTAGE ..............26

MAXIMUM WATTAGE .....................26

4.6.2 CALCULATING LOAD .........................26

4.6.4 WATTAGE CHART ...............................27

5 FIELD OPERATION ................................28

5.1 PREPARE ............................................28

5.2 START ..................................................29

5.2.1 STARTING THE GENERATOR:...........29

5.2.2 STOPPING: .........................................29

5.2.3 EMERGENCY STOPPING: .................29

5.2.4 TERRAIN: ...........................................29

5.2.5 WEATHER: ..........................................29

5.2.6 ELECTRICAL LOADS: .........................29

5.2.7 COMPONENT CONDITION: ...............29

5.2.8 ELECTRICAL HAZARDS: ....................29

5.3 RESIDENTIAL......................................30

5.4.1 TRANSPORTING: ...............................30

5.4.2 LIFTING HOOK: ...................................31

5.4.3 FOLDING HANDLE: ............................31

5.5 STORAGE ...........................................32

5.5.1 PLACING IN STORAGE ......................32

5.5.2 REMOVING FROM STORAGE ...........32

6 SERVICE AND MAINTENANCE ............33

6.1 SERVICE .............................................33

6.1.1 FLUIDS AND LUBRICANTS ................33

6.2 MAINTENANCE ...................................34

6.2.1 GENERAL MAINTENANCE .................34

6.2.2 ENGINE MAINTENANCE ....................34

6.2.3 ALTERNATOR MAINTENANCE ..........34

6.2.4 BATTERY MAINTENANCE .................35

7 SPECIFICATIONS ..................................36

7.1 MECHANICAL......................................36

7.2 BOLT TORQUE ....................................37

8 TROUBLE SHOOTING ...........................38

9 ACCESSORIES ......................................39

10 INDEX .....................................................40

Warranty

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

receipt of the product. Unit or parts shall be returned at the customer’s expense to the authorized service centre. Damage

WARRANTY

Effective on products retailed on or after January 1, 2015.

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

Five (5) Years for Consumer

Two (2) Year for Commercial/Rental

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

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

This warranty does not cover the following items:

1) Parts lost or damaged during shipment,

2) Normal maintenance or adjustments

3) Normal replacement of service items.

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

5) Damages resulting from:

• misuse, negligence, accident, theft or re

• use of improper or insufcient fuel, uids or lubricants

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

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

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

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

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

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

the maintenance of the product.

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

anyone other than an authorized service centre.

If a difculty develops with the product, contact EMB MFG INC. Only our authorized service centres may make repairs to

the product or affect the replacement of defective parts, which will be done at no charge within a reasonable time after the

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

for your les).

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

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

or implied, other than those specied herein.

EMB MFG Inc

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

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

Email: warranty@embmfg.com

rev.270315

WARRANTY IS VOID IF NOT REGISTERED

SurgeMaster

Portable Generator

Check Electrical Connecons

Check Funcon of Generator

Check that Fasteners are ght

Check Engine Fluid Levels

Review Operang and Safety Instrucons

Safety Checks

All Safety Decals Installed

Guards and Shields Installed and Secured

Test GFCI oulets

Review Operang and Safety Instrucons

Backup Power Series: SHS3000, SHS3000R,

SHS5000, SHS5000R, SHS7000, SHS7000R

Jobsite Rated Series: SCS3000, SCS3000R,

SCS5000, SCS5000R, SCS7000, SCS7000R

DELIVERY INSPECTION REPORT

To activate warranty, register your product online at

www.surgemaster.ca

_________________________________________

Customer’s Name

_________________________________________

Contact Name

_________________________________________

Dealer Name

(_________)_______________________________

Phone Number



Pre-Delivery Inspection

Inspect for damage from shipping, immediately contact

the shipping company if damage is found.

_________________________________________

Serial Number

__________ /__________ /__________

Delivery Date

I have thoroughly instructed the buyer on the equipment care, adjustments, safe operation and applicable warranty policy and reviewed the manual.

_________________________________________

Dealer’s Rep. Signature

__________ /__________ /__________ Date

The product manuals have been received by me and I have been thoroughly instructed as to care, adjustments, safe operation and applicable warranty policy.

_________________________________________

Owner's Signature

__________ /__________ /__________ Date

SERIAL NUMBER LOCATION

Always reference the serial number of your SurgeMaster 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. (Serial label location is the same for ALL models)

SERIAL NUMBER LOCATION

Serial Number

Location

Backup Power Series or Jobsite Rated Series Portable Gas Generator

Model Number ____________________________________________________

Serial Number ____________________________________________________

LABEL INFORMATION

As you begin to get familiar with your SurgeMaster product, you will notice that there are numerous labels located on the machine. Here is a brief explanation of what they are for and how to read them.

There are three different types of labelling: safety, informative and product labels.

Safety Labels are pictorial with a yellow background and generally 2 panel. The top panel shows the safety alert (the potential hazard) and the bottom panel shows the message (how to avoid the hazard).

Safety Notice Labels are pictorial with a blue background and generally rectangular with single or multiple symbols. The label illustrates requirements for safe operation (safety equipment, housekeeping etc). These labels are accompanied by detailed instructions in the owners manual, with the label illustrated along side.

Informative Labels are generally pictorial with a white background and can vary to the number of panels. The label will illustrate the function of a feature and is accompanied by detailed instructions in the owners manual, with the label illustrated along side.

Product Labels are associated with the product and carry various messages (model, serial, etc).

Maintenance Labels are associated with the product and carry various messages. They are generally

pictorial. They may be round or rectangular, have a green background and can vary to the number of panels. The label may illustrate the type maintenance and frequency in time between services. Labels are accompanied by detailed instructions in the owners manual, with the label illustrated along side.

See the section on safety signs for safety label denitions. For a complete illustration of labels and label locations, download the parts manual for your model product at www.embmfg.com.

safety alert

message

Z94207

safety label

1 INTRODUCTION

Congratulations on your choice of the SurgeMaster Generator. This equipment has been designed and manufactured to meet the needs of a home owner, business operator or industry that needs electric power during power outage, at a remote location or any time remote power is needed.

Safe, efcient and trouble free operation of your SurgeMaster Generator requires that you and anyone

else who will be using or maintaining the generator, review this SurgeMaster Operators manual and read and understand the Safety, Operation, Maintenance and Trouble Shooting information contained within this Manual.

All SurgeMaster generators are CSA certied and are "neutral bonded to frame" this is a safety feature that means that the neutral line of the electrical circuit has been bonded to the frame of the generator. The purpose is to make fulll advantage of the overcurrent protection device to prevent shocks & electrocution due to a short circuit from a defective cord or device. In effect this will cause the current from a short circuit to travel back to the generator and activate the breaker, instead of through a person to ground

The

SurgeMaster Backup Power Series generator reliable source of continuous power for the home owner, or Utilizing robust gas powered engines to provide a steady and dependable source of power,

in case of power outage,

or when the need arises. The Backup Power series is intended to be connected directly to the appliance/equipment requiring electrical power. It is not recommended to connect these generators to a home electrical system without appropriate equipment and a qualied electrician to make the connections.

The

SurgeMaster Jobsite Rated Series generator contractor in mind. Equipped with GFCI protected outlets, these generators are a safe and dependable source of continuous power on the job site. Small

and portable, source of power,

the gas powered engines produce a steady and dependable

for all your power tools.

As well having the neutral conductor bonded to the frame, Jobsite Rated generators feature GFCI outlet protection, an OSHA requirement when using portable electrical equipment on job sites.

From home owners, recreational use campers, hunters, snowmobilers, to jobsite contractors, decks, docks, & fence builders, rugged roll-cage frame to stand-up to jobsite demands, the SurgeMaster line-up of generators will get you up and running.

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.

7000 series generators require a U1 Lawn & Garden style battery available from your dealer.

Call your SurgeMaster dealer or the Distributor 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 facing the control panel

is designed to be a

recreational use.

are designed with the

SHS3000 / SHS3000R SCS3000 / SCS3000R

SHS5000 / SHS5000R SCS5000 / SCS5000R

SHS7000 / SHS7000R SCS7000 / SCS7000R

2 SAFETY

SAFETY ALERT SYMBOL

This Safety Alert symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

Why is SAFETY important to you?

3 Big Reasons

SIGNAL WORDS:

Note the use of the signal words DANGER, WARNING and CAUTION with the safety

messages. The appropriate signal word for each message has been selected using the

following guide-lines:

The Safety Alert symbol identies important safety messages on the SurgeMaster 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.

Accidents Disable and Kill Accidents Cost Accidents Can Be Avoided

DANGER - Indicates an imminently hazardous

situation that, if not avoided, will result in death or serious injury. This signal word is to be limited to the most extreme situations typically for machine components which, for functional purposes, cannot be guarded.

If you have any questions not answered in this manual or require additional copies or the manual is damaged, please contact your dealer or SurgeMaster, 4144 Boomer Line, St. Clements, ON, N0B 2M0. Phone (519) 699-9283 or Fax (519) 699-4146.

WARNING - Indicates a potentially hazardous

situation that, if not avoided, could result in death or serious injury, and includes hazards that are exposed when guards are removed. It may also be used to alert against unsafe practices.

CAUTION - Indicates a potentially hazardous

situation that, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices.

SAFETY

YOU are responsible for the SAFE operation

and maintenance of your SurgeMaster Portable Generator. YOU must ensure that you and anyone else who is going to use, maintain or work around the generator be familiar with the use and maintenance procedures and related SAFETY information contained in this manual. This manual will take you step-by-step through your working day and alerts you to all good safety practices that should be used while using the Generator.

Remember, YOU are the key to safety. Good safety practices not only protect you but also the people around you. Make these practices a working part of your safety program. Be certain that EVERYONE using this equipment is familiar with the recommended use and maintenance procedures and follows all the safety precautions. Most accidents can be prevented. Do not risk injury or death by ignoring good safety practices.

2.1 SAFETY DO'S & DON'TS'

• DO give operating instructions to operators or

employees before allowing them to operate the machine, and REVIEW annually thereafter.

• DO NOT run a generator indoors, a generator’s exhaust contains toxic carbon monoxide, which you cannot smell or see. Breathing carbon monoxide can be lethal.

• DO read and understand ALL Safety and Operating instructions in the manual and follow them. Most accidents can be avoided. The most important safety device on this equipment is a SAFE operator.

• DO NOT expect a person who has not read and understood all use and safety instructions to operate the machine. An untrained operator is not qualified and exposes himself and bystanders to possible serious injury or death. It is the owners responsibility to the operator to ensure familiarity and understanding of the machine.

• DO NOT modify the equipment in any way. Unauthorized modification may impair the function and/or safety and could affect the life of the equipment.

• DO NOT risk injury or death by ignoring good safety practices.

• DO review safety related items annually with all personnel who will operating or maintaining the generator

• DO have a rst-aid kit available for use should the need arise and know how to use it.

• DO read and understand all safety signs located on the machine before using, maintaining, adjusting or cleaning the generator

• DO have a re extinguisher suitable for electrical res available, should the need arise and know how to use it.

• DO inspect and secure all guards before starting.

• DO wear appropriate protective gear. This list includes but is not limited to:

• Heavy gloves

• Hearing

protection

• Protective shoes with slip resistant

soles

• Protective

glasses, goggles or face shield

• DO prepare before servicing, adjusting, repairing or unplugging:

• stop the machine, disconnect load

• shut off the engine,

• wait for all moving parts to stop

• clear the area of people, especially small

children.

• DO wear suitable ear protection for prolonged exposure to excessive noise.

• DO operate on dry level ground away from combustibles.

• DO NOT touch hot engine parts, mufer, mufer cover, engine body, engine oil, etc. during operation and after the engine has been shut off. Contact may cause burns.

• DO NOT modify the control panel wiring or any grounding on the generator

• DO think SAFETY! Work SAFELY!

2.2 EQUIPMENT SAFETY GUIDELINES

Z94216

Safety of the operator and bystanders is one of the main concerns in designing and developing equipment. However, every year many accidents occur which could have been avoided by a few seconds of thought and a more careful approach to handling equipment. You, the operator, can avoid many accidents by observing the following precautions in this section. To avoid personal injury or death, study the following precautions and insist those working with you, or for you, follow them.

1. In order to provide a better view, certain photographs or illustrations in this manual may show an assembly with a safety shield removed. However, equipment should never be used in this condition. Keep all shields in place. If shield removal becomes necessary for repairs, replace the shield prior to use.

2. Replace any safety sign or instruction sign that is not readable or is missing. Location of such safety signs is indicated in this manual.

3. Never use alcoholic beverages or drugs which can hinder alertness or coordination while using this equipment. Consult your doctor about using this machine while taking prescription medications.

4. Under no circumstances should young children be allowed to work with this

equipment. Do not allow persons to use

this until they have read this manual and have developed a thorough understanding of the safety precautions and of how it works.

Review the safety instructions with all users annually.

5. This equipment is dangerous to children and persons unfamiliar with its operation. The operator should be a responsible, properly trained and physically able person familiar with machinery and familiar with this equipment's operations. If the elderly are assisting with work, their physical limitations need to be recognized and accommodated.

6. Never exceed the limits of a piece of machinery. If its ability to do a job, or to do so safely, is in question - DON'T TRY IT.

7. Never run a generator indoors, a generator’s exhaust contains toxic carbon monoxide, which you cannot smell or see. Breathing carbon monoxide can be lethal.

8. Do not modify the equipment in any way. Unauthorized modication may result in serious injury or death and may impair the function and life of the equipment.

9. In addition to the design and conguration of this equipment, including Safety Signs and Safety Equipment, hazard control and accident prevention are dependent upon the awareness, concern, prudence, and proper training of personnel involved in the operation, transport, maintenance, and storage of the machine. Refer also to Safety Messages and operation instruction in each of the appropriate sections of the engine and machine manuals. Pay close attention to the Safety Signs afxed to the machine.

10. Safe condition involves the following procedure:

• Flip main switch "off" or disconnect all loads

• Shut off the engine.

• Ensure all components have stopped moving.

Safe Condition procedure should be performed before any service, maintenance work or storage preparation.

2.3 SAFETY TRAINING

2.4 PREPARATION

1. Train all new personnel and review instructions frequently with existing workers. Safety is a primary concern in the design and manufacture of our products. Unfortunately, our efforts to provide safe equipment can be wiped out by a single careless act of an operator or bystander.

2. In addition to the design and conguration of equipment, hazard control and accident prevention are dependent upon the awareness, concern, prudence and proper training of personnel involved in the operation, transport, maintenance and storage of this equipment.

3. It has been said, "The best safety feature is an informed, careful operator." We ask you to be that kind of an operator. It is the operator's responsibility to read and understand ALL Safety and Use instructions in the manual and to follow these. Accidents can be avoided.

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:

• Reads and understands the operator's

manuals.

• Is instructed in safe and proper use of

the equipment.

• Understands and knows how to perform

the "safe condition" procedure:

• Flip main switch "off" or disconnect all loads

• Shut off the engine.

• Ensure all components have stopped

moving.

5. Know your controls and how to stop the engine and machine quickly in an emergency. Read this manual and the one provided with your engine.

6. Be certain only a properly trained and physically able person will use the machinery. A person who has not read and understood all using and safety instructions is not qualied to use the machine. An untrained operator exposes himself and bystanders to possible serious injury or death. If the elderly are assisting with the work, their physical limitations need to be recognized and accommodated.

1. Never use the engine and machine until the operators have been adequately trained in the safe operation of the machine and have read and completely understand:

• Safety, Operation and Feature sections of

this manual,

• Engine Operator's Manual

• Each of the Safety Messages found on the

safety signs on the engine and machine.

2. Personal protection equipment including:

• safety glasses

• safety shoes

• gloves

• hearing protection

are recommended during assembly, installation, operation, adjustment, maintaining, repairing, removal, cleaning, or moving the generator. Do not allow long hair, loose tting clothing or jewellery to be around equipment.

3. PROLONGED EXPOSURE TO LOUD NOISE MAY CAUSE PERMANENT HEARING LOSS!

Power equipment can often be noisy enough to cause permanent, partial hearing loss. We recommend that you wear hearing protection on a fulltime basis. Noise over 85dB on a long-term basis can cause severe hearing loss. Noise over 90db adjacent to the Operator over a long-term basis may cause permanent, total hearing loss.

4. Clear working area of stones, branches or hidden obstacles that might be hooked or snagged, causing injury or damage.

5. Use only in daylight or good articial light.

6. Be sure machine is properly mounted, adjusted and in good operating condition.

7. Ensure that all safety shielding and safety signs are properly installed and in good condition.

8. If fuel is on site, store it well away from the machine and ammable materials.

9. Perform the "PreOperation Checklist" procedure before starting work.

2.5 MAINTENANCE SAFETY

1. Good maintenance is your responsibility. Poor maintenance is an invitation to trouble.

2. Follow good shop practices.

• Keep service area clean

and dry.

• Be sure electrical outlets

and tools are properly grounded.

• Use adequate light for

the job at hand.

3. Make sure there is plenty of ventilation. Never operate the machine or the towing vehicle in a closed building. The exhaust fumes may cause asphyxiation.

4. Put the machine in safe condition before working on this machine:

• Flip main switch "off" or disconnect all loads

• Shut off the engine.

• Ensure all components have stopped moving.

5. Allow the engine to cool before performing maintenance, engine components and oil may be hot enough to cause injury.

6. Never work under equipment unless it is blocked securely.

7. When performing any service or maintenance work always use personal protection devices such as

• safety glasses,

• hand protection - gloves

• hearing protectors

• safety shoes

8. Where replacement parts are necessary for periodic maintenance and servicing, genuine factory replacement parts must be used to restore your equipment to original specications. The manufacturer will not be responsible for injuries or damages caused by use of unapproved parts and/or accessories.

9. An appropriate re extinguisher (electrical res) and rst aid kit should be kept readily accessible while performing maintenance on this equipment.

10. Inspect and tighten all bolts, nuts and screws and check that all electrical and fuel connections are properly secured to ensure generator is in a safe condition.

11. When completing a maintenance or service function, make sure all safety shields and devices are installed before placing the generator in service.

12. When performing maintenance on this equipment always have at least 2 workers present. Do not work alone in case an emergency should arise.

13. When cleaning any parts, do not use gasoline but use regular cleanser.

14. Always use proper tools, that are in good condition. Make sure you understand how to use them, before performing any service work.

2.6 BATTERY SAFETY

Caution: Poison / Danger - Causes

Severe Burns. The battery contains sulphuric acid. Avoid contact with skin, eyes or clothing. Keep out of reach of children.

1. Wear gloves and safety glasses or face shield when working on or near batteries.

2. Use a battery carrier to lift the battery or place hands at opposite corners to avoid spilling acid through the vents.

3. Avoid contact with battery electrolyte: External Contact: Flush immediately with water. Eye Contact: Flush with water for 15 minutes. Get prompt medical attention. Clean up any spilled electrolyte immediately.

4. Avoid contact with battery posts, terminals and related accessories, they contain lead and lead compounds, chemicals known to cause harm. Wash hands immediately after handling battery.

5. Keep all sparks and ames away from batteries, as gas given off by electrolyte is explosive.

6. To avoid injury from spark or short circuit, disconnect battery ground cable before servicing any part of the electrical system.

7. FROZEN BATTERIES CAN EXPLODE and result in death or serious injury. DO NOT jump start / charge a frozen battery. Let battery thaw before charging.

8. DO NOT use or charge the battery if its uid level is below the LOWER mark.

Z94216

Z94222

2.7 REFUELING SAFETY

1. Allow the engine to cool if the generator has been in operation.

2. Refuel only outdoors in a well-ventilated area with the engine off.

3. Never smoke near fuel, and keep other ames and sparks away.

4. Do not overll the fuel tank.

5. Always store fuel in an approved container. Make sure that any spilled fuel has been wiped up before starting the engine.

2.8 OPERATING SAFETY

1. Please remember it is important that you read and heed the safety signs on the generator. Clean or replace all safety signs if they cannot be clearly read and understood. They are there for your safety, as well as the safety of others. The safe use of this machine is strictly up to you, the operator.

2. All things with moving parts are potentially hazardous. There is no substitute for a cautious, safe-minded operator who recognizes potential hazards and follows reasonable safety practices. The manufacturer has designed this generator to be used with all its safety equipment properly attached, to minimize the chance of accidents. Read and understand operator's manual before starting, to make sure you have all safety equipment attached and operational.

3. Close and secure all covers, guards, deectors and shields before starting and operating.

4. Never run a generator indoors, a generator’s exhaust contains toxic carbon monoxide, which you cannot smell or see. Breathing carbon monoxide can be lethal.

5. Do not operate near openings to any building that can be occupied in order to help avoid the exhaust hazard.

6. Personal protection equipment including hearing protection, safety glasses, safety shoes, and gloves are recommended during assembly, installation, operation, adjustment, maintaining, repairing, removal, or moving.

7. Inspect electrical harness, and controller to ensure they are in good condition before operating to maintain control.

8. Keep the generator dry. Operate on a dry surface under an open well ventilated, covered structure.

9. Never use alcoholic beverages or drugs which can hinder alertness or coordination while operating this equipment. Consult your doctor about operating this machine while taking prescription medications.

10. Never allow children or unauthorized people to operate or be around this machine.

11. Plug appliances directly into generator or use a heavy-duty outdoor-rated extension cord. Make sure entire extension cord is free of cuts or tears and the plug has all 3 prongs, especially a grounding pin.

12. If necessary to connect generator to house wiring to power appliances, have a qualied electrician install appropriate equipment. Or, your utility company may be able to install an appropriate transfer switch.

13. Keep the working area clean and free of debris to prevent tripping. Operate only on level ground.

14. Parts of a generator become very hot during operation and remain hot for a time after stopping the engine. Be careful not to touch the mufer while it is hot. Let the engine cool before storing the generator indoors.

15. To prevent a possible re, keep the generator at least 3 feet (1 meter) away from building walls and other equipment during operation. Do not place ammable objects close to the engine.

16. NEVER plug the generator into a wall outlet. This practice, known as backfeeding, can cause an electrocution risk to utility workers and others served by the same utility transformer.

Z94221

2.9 TRANSPORT SAFETY

1. Comply with Provincial / state and local laws governing safety and transporting of machinery on public roads.

2. Do not exceed a safe travel speed. Slow down for rough terrain and cornering.

3. Do not transport or move the generator with the engine running.

4. Inspect all access panels and guards to ensure they are secured.

5. If the generator has been running, allow the engine to cool for at least 15 minutes before loading the generator on the transport vehicle. A hot engine and exhaust system can burn you and may ignite some materials.

6. Ensure the fuel tank cap is on tight and keep the generator level when transporting to reduce the possibility of fuel leakage.

7. Move the fuel valve lever to the OFF position.

8. When using ropes or tie-down straps to secure the generator for transportation, be sure to only use the frame bars as attachment points. Do

not fasten ropes or straps to any portions of the

generator body.

9. Do not drink and drive.

10. Just before transport, perform a circle check to ensure everything is safe and secure.

2.11 ELECTRICAL SAFETY

1. The generator produces enough electric power to cause a serious shock or electrocution if misused.

2. Using a generator or electrical appliance in wet conditions (rain or snow), or near a pool or sprinkler system, or when your hands are wet, could result in electrocution. Keep the generator and the immediate area dry.

3. If the generator has been outdoors, unprotected from the weather, check all of the electrical components on the control panel before each use. Moisture can cause a short circuit in electrical components that could result in electrocution.

4. Do not connect to a building’s electrical system unless an transfer / isolation switch has been installed by a qualied electrician.

5. NEVER tamper with the factory settings of the engine or engine governor. Engine speed controls the frequency portion of the electrical output (60hZ). Personal injury or damage to the engine or equipment can result if operating in speed ranges above the maximum or below the minimum allowable.

2.10 STORAGE SAFETY

1. Store the unit in a well vented area away from human activity.

2. If possible, store in a dry area, avoid storage areas with high humidity, because that promotes rust and corrosion.

3. Avoid any area where power tools are operated or spark-producing electric motors.

4. Do not allow children to play on or around the stored machine.

5. Place the generator on a level surface. Tilting or laying it on its side can cause fuel or oil leakage. Support the frame with planks if required.

6. Allow the engine / exhaust to cool. A hot engine and exhaust system can ignite or melt some materials.

7. With the engine and exhaust system cool, cover the generator to keep out dust.

8. Do not use a nonporus sheet as a dust cover. A nonporous cover will trap moisture around the generator, promoting rust and corrosion.

2.12 GAS MOTOR SAFETY

14. DO NOT crank engine with spark plug removed. If engine is ooded, crank until engine starts.

BEFORE STARTING ENGINE, READ AND UNDERSTAND THE OPERATING AND MAINTENANCE INSTRUCTIONS THAT CAME WITH YOUR ENGINE.

WARNING: DO NOT

1. DO NOT run engine in an enclosed area. Exhaust gases contain carbon monoxide, an odourless and deadly poison.

2. DO NOT place hands or feet near moving or rotating parts.

3. DO NOT store, spill, or use gasoline near an open ame, or devices such as a stove, furnace, or water heater which use a pilot light or devices which can create a spark.

4. DO NOT refuel indoors where area is not well ventilated. Outdoor refuelling is preferred.

5. DO NOT refuel while engine is running. Allow engine to cool for 5 minutes before refuelling. Store fuel in approved safety containers.

15. DO NOT strike ywheel with a hard object or metal tool as this may cause ywheel to shatter in operation. Use proper tools to service engine.

16. DO NOT operate engine without a mufer. Inspect periodically and replace, if necessary. If engine is equipped with a mufer deector, inspect periodically and replace, if necessary with correct deector.

17. DO NOT operate engine with an accumulation of grass, leaves, dirt or other combustible materials in the mufer area.

18. DO NOT use this engine on any forest covered, brush covered, or grass covered unimproved land unless a spark arrester is installed on the mufer. The arrester must be maintained in effective working order by the operator. In the state of California the above is required by law (Section 4442 of the California Public Resources Code). Other states may have similar laws. Federal laws apply on federal land.

19. DO NOT touch hot mufer, cylinder or ns because contact may cause burns.

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

7. DO NOT operate engine if gasoline is spilled. Move machine away from the spill and avoid creating any ignition until gasoline has evaporated.

8. DO NOT smoke while lling fuel tank.

9. DO NOT choke carburetor to stop engine. Whenever possible, gradually reduce engine speed before stopping.

10. DO NOT run engine above rated speeds. This may result in injury.

11. DO NOT tamper with governor springs, governor links or other parts which may increase the governed speed.

12. DO NOT tamper with the engine speed selected by the original equipment manufacturer.

13. DO NOT check for spark with spark plug or spark plug wire removed.

20. DO NOT run engine with air cleaner or air cleaner cover removed.

WARNING: DO

1. ALWAYS DO remove the wire from the spark plug when servicing the engine or equipment to prevent accidental starting. Disconnect the negative wire from the battery terminal if equipped with a 12 volt starting system.

2. DO keep cylinder ns and governor parts free of grass and other debris which can affect engine speed.

3. DO examine mufer periodically to be sure it is functioning effectively. A worn or leaking mufer should be repaired or replaced as necessary.

4. DO use fresh gasoline. Stale fuel can gum carburetor and cause leakage.

5. DO check fuel lines and ttings frequently for cracks or leaks. Replace if necessary.

2.13 SIGN-OFF FORM

SurgeMaster follows the general Safety Standards specied by the American Society of Agricultural and Biological Engineers (ASABE) and the Occupational Safety and Health Administration (OSHA). Anyone who will be using and/or maintaining the Portable Generator must read and clearly understand ALL Safety, Usage and Maintenance information presented in this manual.

Do not use or allow anyone else to use this generator until such information has been reviewed. Annually review this information before the season start-up.

Make these periodic reviews of SAFETY and OPERATION a standard practice for all of your equipment. We feel that an untrained operator is unqualied to use this machine.

A sign-off sheet is provided for your record keeping to show that all personnel who will be working with the equipment have read and understand the information in the Operator’s Manual and have been instructed in the operation of the equipment.

SIGN-OFF FORM

DATE

EMPLOYEES SIGNATURE EMPLOYERS SIGNATURE

3 SAFETY SIGNS

Z94221

Z94225

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.

5. Safety signs are available from your authorized Distributor or Dealer Parts Department or the factory.

3.1 HOW TO INSTALL SAFETY SIGNS:

• Be sure that the installation area is clean and dry.

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

• Determine exact position before you remove the backing paper.

• Remove the smallest portion of the split backing paper.

• Align the sign over the specied area and carefully press the small portion with the exposed sticky

backing in place.

• Slowly peel back the remaining paper and carefully smooth the remaining portion of the sign in place.

• Small air pockets can be pierced with a pin and smoothed out using the piece of sign backing paper.

3.2 SAFETY SIGN EXPLANATIONS:

Caution: A generator produces enough

electrical power to cause serious shock or electrocution. Using a generator in wet conditions such as in rain or snow, , or with wet hands could result in electrocution. Keep the generator dry.

Caution: Do not refuel the machine while smoking or when near open ame or sparks. Fuel is highly ammable, handle with care.

Caution: Parts of a generator become very hot during operation and remain hot for a time after stopping the engine. Be careful not to touch the mufer while it is hot. Let the engine cool before storing the generator indoors.

Z94222

Using a generator indoors CAN KILL YOU IN MINUTES. Generator

Exhaust contains carbon monoxide. This is a poison you cannot see

L'utilisation d'un générateur àl'intérieur PEUT VOUS FAIRE MOURIR

NEVER use inside a home or

maisonoudans dessecteurs partiellement inclustelsque des garages,MÊMESIles portes et

DANGER!

EN MINUTES. L'échappement contient le monoxyde de carbone,

garage, EVEN IF doors and

N'employerJAMAIS dans la

lesfenetressoientouvertes.

or smell.

Ceci est un toxiqueque vous ne pouveznivoirnisentir.

Only use OUTSIDE and far away from windows, doors,

windows are open.

and vents.

Employer seulemer DEHORS

et loin de fenêtres, desporte

et des ventilateurs.

Danger: Never run a generator indoors, a generator’s exhaust contains toxic carbon monoxide, which you cannot smell or see. Breathing carbon monoxide can be lethal.

Caution: Read and understand ALL safety and operating instructions in the manual, read and understand ALL safety labels located on the machine. The most important safety device on this equipment is an informed SAFE operator.

NEUTRAL BONDED TO FRAME

NEUTRE RACCORDÉ AU BÂTI

Note: This is a

safety feature and

Z94170

indicates that the neutral line of the electrical circuit has been bonded to the frame of the generator.

3 SAFETY SIGN LOCATIONS

Z94215

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!

Z94255 On Both Sides

Models Without Electric

Start

DANGER!

Using a generator indoors CAN KILL YOU IN MINUTES. Generator

Exhaust contains carbon monoxide. This is a poison you cannot see

L'utilisationd'ungénérateur àl'intérieur PEUT VOUS FAIRE MOURIR

EN MINUTES. L'échappement contient le monoxyde de carbone,

or smell.

Ceci est un toxiqueque vous ne pouvez ni voir ni sentir.

Using a generator indoors CAN KILL YOU IN MINUTES. Generator

Exhaust contains carbon monoxide. This is a poison you cannot see

L'utilisationd'ungénérateur àl'intérieur PEUT VOUS FAIRE MOURIR

EN MINUTES. L'échappement contient le monoxyde de carbone,

DANGER!

or smell.

Ceci est un toxiqueque vous ne pouvez ni voir ni sentir.

NEVER use inside a home or

garage, EVEN IF doors and

windows are open.

N'employerJAMAIS dans la

maisonoudans dessecteurs partiellement inclustelsque des garages,MÊMESIles portes et

les fenetressoientouvertes.

0°

Only use OUTSIDE and far away from windows, doors,

and vents.

Employer seulemer DEHORS

et loin de fenêtres, desporte

et des ventilateurs.

Z94225

Z94252 On Both Sides

Models With Electric

Start

Z94255

NEVER use inside a home or

garage, EVEN IF doors and

windows are open.

N'employerJAMAIS dans la

maisonoudans dessecteurs partiellement inclustelsque des garages,MÊMESIles portes et

les fenetressoientouvertes.

REMEMBER - If safety signs have been damaged, removed, become illegible or parts replaced without safety signs, new signs must be applied. New safety signs are available from your authorized dealer.

Only use OUTSIDE and far away from windows, doors,

and vents.

Employer seulemer DEHORS

et loin de fenêtres, desporte

et des ventilateurs.

Z94225

Z94222

Z94216

Z94221

Z94252

4 OPERATION & FEATURES

OPERATING SAFETY

• Read and understand operator's manual before starting. Review safety instructions annually.

• Stop and disable engine, and wait for all moving parts to stop before servicing, adjusting or repairing.

• To prevent electrical shocks, do not operate this generator in the rain or with wet hands. Generator should be kept dry and not operated on wet or damp surfaces.

• Close and secure all guards, deectors and shields before starting and operating.

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

• Do not operate with damaged or defective extension cords, or power cords. Protect the cord from getting pinched or crushed if it passes through a window or doorway.

• Use properly rated, grounded 3-prong extension cords, tools, and appliances.

• Do not operate this generator indoors, or in areas with poor ventilation. The exhaust fumes contain carbon monoxide, a poisonous, odourless, 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 ames, pilot lights or sparking electrical devices (e.g. power tools, welders or grinders).

• To prevent a possible re, keep the generator at least 1 meter (3 feet) away from building walls and other equipment during operation.

• Do not place ammable objects close to the engine.

• The engine should be refuelled in a well-lit, adequately vented 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. Overheating can result in damaged equipment.

• For storage, do not cover the generator until it has cooled down completely.

• The ambient temperature should not exceed 100° F/40° C.

DO NOT attempt to crank or start the engine

before it has been properly lled with the recommended amount and type of oil.

4.1 TO THE NEW OPERATOR OR OWNER

The SurgeMaster Portable Generators are designed to provide portable electrical power to equipment that is not connected to the electrical grid system.

It is the responsibility of the owner or operator to read this manual and to train all other operators before they start working with the machine. Follow all safety instructions exactly. Safety is everyone's business. By following recommended procedures, a safe working environment is provided for the operator, bystanders and the area around the work site.

Untrained operators are not qualied to use the

machine.

Many features incorporated into this machine are the result of suggestions made by customers like you. Read this manual carefully to learn how to use the Generator safely and how to set it to provide maximum field efficiency. By following these instructions in conjunction with a good maintenance program, your Portable Generator will provide many years of trouble-free service.

4.1.1 SAFE CONDITION

Ensure all operators understand how to put the machine in safe condition before working with

this machine,

• Flip main switch "off" or disconnect all loads

• Shut off the engine.

• Ensure all components have stopped moving.

4.2 MACHINE COMPONENTS

Engine

Alternator

Continuous

Maximum

SurgeMaster Portable Generators consists of several models of generators. Although slightly different for each model, controls and power outlets are mounted in similar locations for convenient access and operation.

Series Model

SHS3000 163cc 2.9 2100 2500

SHS3000R 163cc 2.9 2100 2500

SHS5000 270cc 4.9 4250 5000

SHS5000R 270cc 4.9 4250 4600

SHS7000 389cc 6.8 6250 6500

SHS7000R 389cc 6.8 6250 6700

SCS3000 163cc 2.9 2100 2500

SCS3000R 163cc 2.9 2100 2500

The unit is designed to provide electrical power for work (Jobsite Rated series) or home (Backup Power series). Each outlet is designed with a circuit breaker to protect against overload. For protection against electrical shocks from short circuits, the machine is neutral bonded to the frame. The entire assembly is mounted within the frame for added protection and convenient access.

wattage

All SurgeMaster generators are CSA certied and have the safety feature

of the neutral conductor bonded to the frame, an OSHA requirement when

Engine

See "Controls" section and engine owners manual for more engine information.

SCS5000 270cc 4.9 4250 5000

SCS5000R 270cc 4.9 4250 4600

SCS7000 389cc 6.8 6250 6500

SCS7000R 389cc 6.8 6250 6700

Note:

using portable electrical equipment on job sites.

Outlets

Circuit

Breaker

Frame

4.3 MACHINE BREAK-IN

Check and lubricate the machine per the schedule outline

Exhaust gas contains poisonous carbon monoxide. Never

Check all electrical connections. Replace, repair or clean

Make sure that all lids, guards and shields are in place,

Check condition of the battery and other electrical

Check the fuel level, Starting with a full tank will help to Check engine fluid levels. Top up as required. Refer to the

Check the air filter

Check all power cords that will be used, ensure they are in good repair.

Check that the alternator cooling air intake and discharge

4.4 PREOPERATION CHECKLIST

Although there are no operational restrictions on the portable generator when used for the rst time, it is recommended that the following mechanical items be checked:

DO NOT attempt to crank or start the engine

before it has been properly lled with the

recommended amount and type of oil.

A. After operating for 1 hour:

1. Ensure the machine is in safe condition before checking any components. (see

4.1.1)

2. Review the engine operators manual for break-in.

3. Inspect the axle, tires, and wheels.

4. Torque all fasteners and hardware.

5. Check that the alternator cooling air intake and discharge openings are free and unblocked

6. Check condition of electrical components and connectors. Keep all components / connectors in good condition.

B. After operating for 8 hours:

1. Repeat steps 1 through 6 listed above. (Section A)

2. Go to the normal servicing and maintenance schedule as dened in the Maintenance Section.

Air Discharge

Efcient and safe operation of the SurgeMaster Portable Generator requires that each operator reads and understands the use procedures and all related safety precautions outlined in this section.

A PreOperation checklist is provided for the operator. It is important for both the personal safety and maintaining good mechanical condition that this checklist is followed.

Before operating the SurgeMaster Portable Generator and each time thereafter, the following areas should be checked off:

Pre-Operation Checklist

in the Maintenance Section.

run the generator in an enclosed area. Be sure there is adequate ventilation in the work area.

as required.

secured and functioning as designed.

components. Keep all components in good condition.

eliminate or reduce operating interruptions for refueling.

engine operators manual.

Air Intake

Ensure alternator openings

are free and unblocked

openings are free and unblocked

4.5 CONTROLS

Please review this section to familiarize yourself with the location and function of each control before starting. The controls of the SurgeMaster generators are laid out so that they are easy to see and use. Familiarizing yourself with the controls will enable you to take advantage of all the features available on the SurgeMaster generators and apply them as conditions demand.

4.5.1 ENGINE CONTROLS

Always read the engine operator's manual supplied with the machine to familiarize yourself with its operating and starting procedure details. Generator Models And Engines:

SHS3000 & SHS3000R.......................GX160 SCS3000 & SCS3000R.......................GX160

SHS5000 & SHS5000R.......................GX270 SCS5000 & SCS5000R.......................GX270

SHS7000 & SHS7000R.......................GX390 SCS7000 & SCS7000R.......................GX390

The GX270 engine is described in the illustration below. The GX160 and GX390 are similar in layout with the exception of the ignition switch on the GX390, which is located on the control panel.

1. Ignition Switch: This switch controls the electric power to the engine.(GX160 & GX270)

2. Throttle: The throttle is preset and locked to run at optimum RPM and is not adjustable. Engine RPM directly affects output from the alternator, and therefore the RPM should never be adjusted.

3. Choke: (GX160) This slide lever controls the position of the choke. Close the choke for starting when the engine is cold. Open the choke as the engine warms. Always fully open the choke when operating the machine. (GX270 & 390 feature auto choke)

4. Starting Rope: Pull sharply on the starting rope T bar when starting the engine. Release the T bar when engine is running.

5. Electric Start: (GX390) This switch controls the electric power to the engine, turn ignition switch located on control panel to start the engine. Release the switch once engine starts.

6. Fuel Shut-Off Valve: This valve controls the ow of fuel to the engine. Turn the valve on when running the engine and off when refuelling or not in use.

Choke

GX160

Fuel

Shut-off

Ignition Switch

Starting

Rope

GX270

GX390

Electric Start

4.5.2 ELECTRICAL PANEL FEATURES

SurgeMaster Standard Series generators have models available with a range of features. All standard generators feature a reliable Honda engine, large fuel tanks for extended run time, and a heavy duty wheeled frame with fold away handle.

Some models feature: AVR (auto voltage regulation): an electronic circuit, designed to automatically maintain a constant voltage level through a range of loads.

AVR indicator light shows the status of AVR:

• Indicator is on steady: Load is within range and voltage is being regulated.

• Indicator is ashing quickly: Load is too high and voltage is dropping out of

acceptable range.

Auto Idle: When there is no load detected, the AVR indicator light will blink slowly, and the engine will slow to an idle. This feature is switchable on or off.

Full Power Feature: When the 240v leg is not used, turning on the full power feature utilizes the secondary winding of the alternator (normally used for 240v) to increase the power capacity of all 120v outlets (5-20R and L5-30). Amperage values in the specication chart are shown with the Full Power feature on. Turning on the full power feature disables the 240v L14-30 receptacle.

Ground terminal: The generator ground terminal is connected to the ground terminals of each receptacle and the frame of the generator. Before using the ground terminal, consult a qualied electrician or electrical inspector for any local codes that apply to the intended use of the generator. Ground and neutral are bonded to the frame.

GROUD FAULT

SENSING MODULE

GCFI Protection: Jobsite Rated Series feature full panel GFCI protection. The main breaker also functions as a ground fault circuit interrupter (GFCI) which is able to detect an imbalance as small as 6 milliamps, and it can react almost instantly to trip the circuit. GFCI circuit protection is a requirement for OSHA.

GFCI Module Function And Testing: In a typical circuit, the current returning to the power supply will be equal to the current leaving the power supply. If the difference between the current leaving and current returning through the GFCI exceeds 6 milliamps, the GFCI opens and de-energizes the circuit.

Normal operating state:

• Power LED is green indicating power is on.

• Circuit breaker is at “on” position.

• Fault indicator LED is off.

Ground fault is detected:

• Power green LED will go out.

• Red fault led will start blinking.

• Circuit breaker will trigger to off position.

Note: An electrical overload is indicated if the breaker trips and the GFCI green power light is still on.

• Switch off or disconnect the load, determine the source of the fault and correct.

• GFCI module will automatically reset, no need to press reset button.

• Turn on the circuit breaker.

• Reconnect the load.

TEST

P O

E R

RESET

F A U L T

RESET

WARNING

TEST BEFORE EACH USE

SEE INSTRUCTIONS

Test GFCI for proper operation before each use. Press test button. The circuit should be de-energized, power green LED will go out, red fault led will start blinking. Push the reset button to reset. Do not operate generator and have the GFCI module inspected by a qualied electrician if GFCI fails this test.

4.5.3 ELECTRICAL PANEL

SHS3000 & SHS3000R

One three prong twist lock outlet is used to provide 120v power. One duplex outlet for 120v power. Full panel is protected by a 15 amp breaker.

125v L5-30

receptacle

SCS3000 & SCS3000R

15 amp main

breaker

125v duplex

receptacle

(5-20R)

AVR indicator

SHS3000R

only

Ground

terminal

15 amp main

breaker

One three prong twist lock outlet is used to provide 120v power. One duplex outlet for 120v power. Full panel is protected by a 15 amp breaker and GFCI module.

125v L5-30

receptacle

2 x 125v duplex

receptacles (5-20R)

SHS5000 & SHS5000R

One three prong twist lock outlet is used to provide 120v power. One four prong twist lock outlet is used to provide 120/240v power. Two duplex outlets for 120v power, protected by 15 amp pop up breakers. Full panel is protected by a 17.5 amp breaker.

AVR indicator

SCS3000R

only

2 x 15 amp pop

up breaker

Full panel GFCI

module

125v duplex

receptacle

(5-20R)

Ground

terminal

125/250v L14-30

receptacle

125v L5-30

receptacle

Full power feature

Hourmeter

Ground

terminal

AVR / Auto

idle indicator.

AVR on

SHS5000R only

Auto idle

control switch

17.5 amp

main breaker

2 x 125v duplex

receptacles (5-20R)

2 x 15 amp pop

up breaker

Full panel GFCI

module

SCS5000 & SCS5000R

Hourmeter

Ground terminal

2 x 125v duplex

receptacles (5-20R)

SHS7000 & SHS7000R

Hourmeter

Ground

terminal

AVR / Auto idle

indicator. AVR on

SCS5000R only

2 x 15 amp pop

up breaker

AVR / Auto idle

indicator. AVR on

SHS7000R only

125/250v L14-30

Full power feature

Auto idle

control switch

125/250v L14-30

Full power feature

Auto idle

control switch

receptacle

125v L5-30

receptacle

17.5 amp

main breaker

receptacle

125v L5-30

receptacle

26 amp main

breaker

2 x 125v duplex

receptacles (5-20R)

SCS7000 & SCS7000R

Hourmeter

Ground terminal

2 x 15 amp pop

up breaker

AVR / Auto idle

indicator. AVR on

SCS7000R only

Full panel GFCI

module

Auto idle

control switch

125/250v L14-30

receptacle

125v L5-30

receptacle

Full power feature

26 amp main

breaker

CIRCUIT BREAKERS:

Z94221

Z94252

Outlets on the electrical panel are protected with circuit breakers to prevent overloading the circuit. If a breaker trips, reduce the load before re-setting the breaker. The pop out breakers control duplex outlets only. The main circuit breaker controls entire panel. On GFCI models, GFCI controls entire panel.

• If a breaker trips:

• the breaker reset pops out or switch trips,

• switch off or disconnect the load,

determine the source of the over load and correct,

• allow the breaker to cool,

• depress the breaker button or reset

switch to reset,

• turn on or reconnect the load

Pop out breakers

Main circuit

breaker

GFCI module

Note: For GFCI full panel protected models: A ground fault is indicated if the breaker trips and the GFCI red fault light is on.

OPERATING HINTS:

• Position frame on a level area to minimize the chance of spilling fuel and maximize the fuel capacity of the tank. Spilled fuel can be ignited by a spark from the electrical power system.

• Do not refuel while the engine is running. Wait until the unit has cooled before refuelling.

• Keep the working area neat and clean to prevent slipping and tripping. Prevent accidents at the work site.

• Always keep the generator and connections dry, do not let water pool around the generator or connections to prevent potential electrocution hazard.

• Position the generator under cover to protect it from rain or bad weather.

• Do not operate when the ambient temperature exceeds 100° F (40° C) to prevent overheating.

• Do not cover the unit during operation to prevent overheating.

IMPORTANT

A circuit breaker that trips

repeatedly indicates a

problem.

Generator in optimum

working conditions

DANGER

Carbon Monoxide Hazard:

Never run a generator indoors. A generator’s exhaust contains toxic carbon monoxide, which you cannot smell or see. Breathing carbon monoxide can be lethal.

Z94216

4.6 ELECTRICAL LOAD

below maximum

Starting

Watts

Running

Watts

Load Calculation Example

4.6.1 WATTAGE AND LOAD

Your SurgeMaster generator has two wattage (power) specications that need to be considered when you are connecting loads: continuous watts and maximum watts. At the same time there are two different types of loads, resistive and reactive.

REACTIVE LOAD

Generally a tool or appliance that contains an electric motor is a reactive load, Reactive loads have two modes of operation: startup and running.

An electric motor starting watts (reactive load) could possibly require up to 3 x its running watts at start up.

In other words wattage will spike at starting and level off to running (continuous) wattage when it is operating normally. (See wattage chart)

RESISTIVE LOAD

A resistive load is lighting, hot plate, TV, etc, Resistive loads generally will not spike and starting wattage is the same as running wattage. (See wattage chart)

CONTINUOUS WATTAGE

Continuous wattage is the wattage range that can be safely generated by the alternator for an extended period.

4.6.2 CALCULATING LOAD

When calculating load in watts, you will need to determine two wattage values:

• running wattage + starting wattage: determine the starting wattage of your reactive loads and add them to the running wattage of your resistive loads.

• running wattage only: add up the running wattage of both the resistive and reactive loads.

Generator Spec: 2000 maximum watt, 1500 continuous watt

Qty Load

Refrigerator/Freezer 1200 192

load calculation ex-

Furnace Fan (1/8 hp) 500 300

ample

Lighting (40w ea) 240 240

Totals

The example totals match the second combination on the chart, and shows that the run status is OK.

Wattage Combination Status

total starting wattage + total running wattage is within the continuous rating

total starting wattage is over the continuous rating but below maximum, and total running wattage is within continuous rating

1940 732

MAXIMUM WATTAGE

Maximum wattage is the wattage range the generator can produce but for only short periods of time (electric motor starting). Drawing maximum wattage for extended periods will cause the breaker to trip.

total starting wattage is over the continuous & maximum rating, and total running wattage is within continuous rating

total starting wattage is over the continuous & maximum rating, and total running wattage is over continuous rating

both the total starting wattage and total running wattage are over the continuous rating but

Stop

50,000 BTU

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.

To determine the wattage, use this formulae: Amps x Volts = Watts (See wattage chart)

Household Wattage Approx. Starting Running Industrial Motors Approx. Starting Running

Coffee Maker 600 600 Split Phase ¼ hp 1700 400

Dish Washer 540 216 Split Phase ½ hp 2600 600

Electric Frying Pan 1500 1500 Capacitor Start Induction Run ¹/

Electric Range 8" Element 2100 2100 Capacitor Start Induction Run 1 hp 2300 1000

Microwave Oven (650 watts) 1000 1000 Capacitor Start Capacitor Run 1-½ hp 4200 1600

Refrigerator/Freezer (Energy Star) 1200 132-192 Fan - ¼ hp 1200 650

Automatic Washer 3400 1200

Clothes Dryer (Electric) 6750 5400

Furnace Fan (1/8 hp) 500 300 Air Compressor (½ hp) 1600 975

Furnace Fan (1/6 hp) 750 500 Air Compressor (1 hp) 4500 1600

Furnace Fan (1/4 hp) 1000 600 Bench Grinder (8") 2500 1400

Furnace Fan (1/3 hp) 1400 700 Hand Drill (½") 900 600

Furnace Fan (1/2 hp) 2350 875 Pressure Washer (1 hp) 3600 1200

Lighting Circular Saw (7 - ¼") 2300 1400

Radio 50-200 50-200 Electric Chain Saw (14", 2hp) 1100 1100

Sump Pump (1/3 hp) 1300 800 230 Amp AC (at 100 amp) 7800 7800

Sump Pump (1/2 hp) 2150 1050 Table Saw (10 Inches) 4500 1800

Television: tube / 43" flat screen 300 / 190 300 / 190 Drill (3/8", 4 amps) 600 440

Air Conditioner (10000 BTU) 2200 1500 Drill (1/2", 5.4 amps) 900 600

Laptop Computer 200-250 200-250

Desktop Computer 600-800 600-800

Monitor (LCD style) 30 30 Electric Fence (25 miles) 250

Printers Milk Cooler 1800 1100

Ink Jet / Ink Jet Multi Function 20 / 250 20 / 250 Milker (Vacuum Pump, 2hp) 2300 1000

DVD Player 350 350

Satelite Receiver 250 250 90,000 BTU 725 500

Fan (portable) 120 40 150,000 BTU 1000 625

add up various wattages

Laser 400-850 400-850 Portable Heater(Kerosene / Diesel

Contractor Approx. Starting Running

Farm Equipment Approx. Starting Running

Battery Charger

60 Amp w/ 250 Amp Boost 1500/5750 1500/5750

100 Amp w/ 300 Amp Boost 2400/7800 2400/7800

Electric Welder (200 Amp AC) 9000 9000

3 hp 975 450

600 400

15 Amp 380 380

5 FIELD OPERATION

OPERATING SAFETY

• Read and understand operator's manual before starting. Review safety instructions annually.

• Stop and disable engine, remove ignition key and place in your pocket and wait for all moving parts to stop before servicing, adjusting or repairing.

• To prevent electrical shocks, do not operate this generator in the rain or with wet hands. Generator should be kept dry and not operated on wet or damp surfaces.

• Close and secure all guards, deectors and shields before starting and operating.

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

• Do not operate with damaged or defective extension cords, or power cords. Protect the cord from getting pinched or crushed if it passes through a window or doorway.

• Use properly rated, grounded 3-prong extension cords, tools, and appliances.

• Do not refuel the engine while it is in operation or still hot. Do not refuel the engine near open ames, pilot lights or sparking electrical devices (e.g. power tools, welders or grinders).

• To prevent a possible re, keep the generator at least 1 meter (3 feet) away from building walls and other equipment during operation.

• Do not place ammable objects close to the engine.

• The engine should be refuelled in a well-lit, adequately vented 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. Overheating can result in damaged equipment.

• For storage, do not cover the generator until it has cooled down completely.

• The ambient temperature should not exceed 100° F/40° C.

The operator has the responsibility of being familiar with all operating and safety procedures and following them.

Although the Portable Generator is easy to use, each operator should review this section to familiarize himself with the detailed safety and operating procedures. When using this machine, follow this procedure:

5.1 PREPARE

• Clear the area of bystanders, especially small children.

• Each operator must be trained and familiar with the set up and operation of the generator and its components.

• Review the machine components. (see Section 4.2)

• Review and follow the PreOperation Checklist. (see Section 4.4).

• Review operation and function of the controls. (see section 4.5)

• Survey the work site, move to a clear, level work area and position at the work site. Do not start the generator until it is in position.

• Review loads section. (see section 4.6).

Ensure all operators understand how to put the machine in safe condition before working with this machine,

• Flip main switch "off" or disconnect all loads

• Shut off the engine.

• Ensure all components have stopped moving.

5.2 START

Please review the engine controls section and the engine owners manual for starting and stopping the engine.

5.2.1 STARTING THE GENERATOR:

• Ensure the main power switch / breaker is in the "off" position or turn all the appliances or electrical loads off.

• Plug in power cords from appliances or loads.

• Ensure the cooling vents around the alternator are free and not blocked

• Pull start: Turn on the ignition switch, pull

sharply on the starting rope T bar to start the engine. (Refer to engine manual for detailed engine starting procedure.)

Electric start (GX390): Turn ignition

switch located on control panel to start the engine. Release the switch once engine starts.

• Run the engine for a few moments until it warms up.

• Flip the main switch / breaker to "on", or switch appliances or electrical loads on.

5.2.2 STOPPING:

• Flip the main power switch / breaker to the "off" position or turn all the appliances or electrical loads off.

• Run the engine for a few moments to allow the engine to cool.

• Switch engine off, unplug all appliances or loads.

5.2.3 EMERGENCY STOPPING:

• Immediately ip off the main breaker

• Turn the engine off.

• Correct the emergency condition before

resuming work and re-starting the engine.

5.2.4 TERRAIN:

The generator works well in a wide variety of operating conditions but it should always be positioned on a level surface. When the frame is level, fuel spillage is minimized and the gas tank capacity is maximized. Do not operate unless the frame is level.

5.2.5 WEATHER:

• Do not operate in the rain, in damp wet conditions or with wet hands. Keep the generator and work area dry to prevent shocks and shorts. Use properly rated, grounded 3-prong extension cords, tools, and appliances.

• Do not operate at temperatures above 100° F (40° C) to prevent overheating of the engine or generator. Always run for a few minutes without an electrical load to help cool the components before shutdown.

5.2.6 ELECTRICAL LOADS:

The generator is ideally suited to camping, farm, household, workshop, construction site or anywhere that back-up power is required. In order to determine the power requirements of your appliance, refer to section 4.6. If the power draw for the appliance exceeds the outlet capacity, the circuit breaker will be tripped. Reduce the current draw and reset the breaker before resuming operation.

5.2.7 COMPONENT CONDITION:

Always use electrical components that are in good condition. Do not use electrical cords, plugs and connectors that are frayed, damaged, cracked or not in good condition. Electrical components that are not in good condition can lead to shocks, shorts or sparking. Any of these conditions can create and lead to an undesirable or unsafe situation.

5.2.8 ELECTRICAL HAZARDS:

The generator is designed to generate an electrical current at a high enough power level to get meaningful work done. However, power at these levels also includes the possibility of electrical hazards. Some things to remember about electrical hazards include but are not limited to:

• Keep all electrical components in good condition.

• Do not operate with frayed, cracked or damaged parts.

• Do not operate if operating in damp or wet conditions.

• Do not operate with wet hands.

5.2.9 ELECTRICAL CORDS

Power cords are rated by AWG number. The lower the AWG number, the thicker the wire (gauge). The thicker the wire the more wattage can travel through it.

Using underrated power cords to supply power to electrical devices may cause over current draw, trip a breaker and potentially damage your device.

Depending on the amp draw or wattage of your appliance, the gauge of the wire in your extension cords becomes a factor in the length of the cord you can use.

Because a wire can cause resistance to the power ow, the thinner the wire, the more the resistance. Similarly, the longer the wire, the more the resistance.

Resistance due to the cord thickness or length keeps the device from getting the power it needs. You may have to increase the thickness of the wire (lower number AWG), or shorten the cord.

5.3 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" it is illegal, extremely dangerous and potentially lethal.

A safer option is to use your generator in a standby conguration. This requires an electrician to install a generator sub panel, connected to the house's main electrical panel. Prepare the generator, run a single extension cord into the sub panel, ip the switch and power the circuits you need.

This eliminates the risk of electrical “back feed”, potentially injuring or killing utility workers repairing downed power lines.

For standby installation: please note that SurgeMaster generators have a "neutral bonded to frame" feature, and requires connection by a

certied electrician when connecting the generator to a house electrical system.

A portable electric generator can provide power for fridges, freezers, sump pump, furnace fan small kitchen appliances, power tools, lights and other comforts of civilization when you are experiencing a power outage.

When not required for home, portable generators can be used to power recreational vehicles, or

put to work on construction sites that have no electrical service, providing clean, reliable power to operate saws, drills, air compressors, heaters, paint sprayers and other AC-powered tools.

Electronics are sensative and may become damaged if subjected to voltage and frequency varitations. SurgeMaster generators equipped with AVR (auto voltage regulation) help to regulate voltage within a range, controlling dips in voltage that could potentialy damage electronics.

However, appliances that have a reactive load (electric motors in fridges, furnaces etc) cause a momentary voltage drop at startup. AVR cannot reacte fast enough compensate for the short drop in voltage. Therefore it is important to consider what loads are connected to your generator along with your electronics.

For example if your 3000w generator has a 50% constant load (lights, heaters etc) and a refridgerator starts up (50% startup wattage) the result is a momentarty voltage drop that could damage sensative electronics.

Decreasing your constant load or increasing the size of your generator will help the AVR to regulate voltage. Another level of protection for your electronics is have them connected to a UPS (uninteruptable power supply) which will act as a lter against voltage drops.

5.4 MOVING

5.4.1 TRANSPORTING:

When transporting from location to location, keep the following points in mind:

• If the generator has been running, allow the engine to cool for at least 15 minutes before loading the generator on the transport vehicle. A hot engine and exhaust system can burn you and can ignite some materials.

• Keep the generator level when transporting to reduce the possibility of fuel leakage. Move the fuel valve lever to the OFF position.

• Do not lay the generator on its side when moving, storing, or during operation. A hazardous condition may be created by oil or fuel leaking.

• Transport when the fuel tank is empty or nearly empty. Turn the fuel line off.

• When using ropes or tie-down straps to secure the generator for transportation, be sure to only use the frame bars as attachment points. Do

not fasten ropes or straps to any portions of the

engine or alternator.

5.4.2 LIFTING HOOK:

SurgeMaster standard generators feature a "sky hook" lifting hook location for lifting with a crane. Lifting locations are indicated by lift hook labels and are located at the centre of balance for the generator.

Lifting at this point is the safest way to lift the generator. Have an extra

Lifting hook

Z94440

5.4.3 FOLDING HANDLE:

SurgeMaster standard generators are equipped with a folding handle to allow for easy transportation.

To raise handle, simply lift the handle, and the latch pins will release. Pivot handle upward until pins engage to lock handle in raised position.

To lower handle, push down on the handle and the latch pins will release. Pivot handle downward until pins engage to lock handle in lowered position.

Latch pins

person with a guide rope attached to the generator to prevent swaying.

Generators without sky hook location are not designed to be lifted by crane.

Do not lift entire generator by folding handle. Folding handle is not intended for motorized transport of generator.

5.5 STORAGE

STORAGE SAFETY

• Store the unit in an area away from human activity, or children playing

• Do not store near any tool, machine, appliance that produces ame or sparks.

• Store the unit in a level area.

5.5.1 PLACING IN STORAGE

After use or when the machine will not be used for a period of time, completely inspect all major systems of the Portable Generator. Replace or repair any worn or damaged components to prevent any unnecessary down time at next use. PLEASE REFER TO THE ENGINE OWNERS MANUAL TO PREPARE THE ENGINE FOR STORAGE Follow this procedure before storing:

1. Remove all plugs or electrical loads from the electrical panel.

2. Thoroughly clean the machine with a damp cloth to remove all dirt, mud or debris. Ensure all the vents on the alternator are clean and clear.

3. Touch up all paint nicks and scratches to prevent rusting.

4. Turn fuel valve off.

5. If the generator is to be stored for longer periods, (over 6 months) follow the engine manufacturers recommendations for storage preparation

6. Store the machine inside in cool dry area. Avoid storage areas with high humidity, because that promotes rust and corrosion.

7. Use a canvas tarp or similar material to keep it covered and free of dust. Avoid plastic or nonporus cover that will trap moisture and promote corrosion.

8. If stored outside (not recommended), keep it sheltered, store it on wooden blocks or a wooden pallet, cover with a waterproof tarpaulin and tie down securely.

9. Store in an area away from human activity.

10. Do not allow children to play around the stored unit.

5.5.2 REMOVING FROM STORAGE

When removing this machine from storage, follow this procedure:

1. Remove the tarpaulin if covered.

2. Review and follow the pre-operation checklist.

3. Check engine operators manual for engine startup after storage.

IMPORTANT

If the machine has been stored for more

than 12 months with fuel, to prevent

hard starting, drain the fuel tank and

replace with fresh fuel.

Cleaned , prepared & ready for storage

(Typical)

6 SERVICE AND MAINTENANCE

MAINTENANCE SAFETY

• Good maintenance is your responsibility. Poor maintenance is an invitation to trouble.

• Read the instructions before you begin, and make sure you have the tools and skills required. Do not smoke or have sources of ignition nearby while performing maintenance.

• Follow good shop practices.

- Keep service area clean and dry.

- Be sure electrical outlets and tools are

properly grounded.

- Use adequate light for the job at hand.

• Make sure there is plenty of ventilation.

Never operate the engine in a closed building. The exhaust fumes may cause asphyxiation.

• Before working on this machine, shut off the engine, disconnect all loads, and turn fuel valve off.

6.1 SERVICE

• Never work under equipment unless it is blocked securely.

• A re extinguisher and rst aid kit should be kept readily accessible while performing maintenance on this equipment.

• Periodically tighten all bolts, nuts and screws and check that all electrical and fuel connections are properly secured to ensure unit is in a safe condition.

• When completing a maintenance or service function, make sure all safety shields and devices are installed before placing unit in service.

• Caution: Burns from hot parts. Let the engine, alternator and exhaust system cool before touching.

• Use only a non-ammable solvent, not gasoline, to clean parts.

6.1.1 FLUIDS AND LUBRICANTS

1. Engine Oil: See engine owners manual for full detail on oil type specic to operating conditions and capacity.

2. Engine Fuel:

See engine owners manual for full detail on fuel types and limitations.

Fuel Tank Capacity: SHS3000 & SHS3000R 18 L (4.75 US gal) SCS3000 & SCS3000R 18 L (4.75 US gal) SHS5000 & SHS5000R 26 L (6.9 US gal) SCS5000 & SCS5000R 26 L (6.9 US gal) SHS7000 & SHS7000R 26 L (6.9 US gal) SCS7000 & SCS7000R 26 L (6.9 US gal)

3. Storing Lubricants:

Your machine can operate at top efciency only if clean lubricants are used. Use clean containers to handle all lubricants. Store them in an area protected from dust, moisture and other contaminants.

DO NOT attempt to crank or start the engine

before it has been properly lled with the

recommended amount and type of oil.

6.2 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,

• Flip main switch "off" or disconnect all loads

• Shut off the engine.

• Ensure all components have stopped moving.

Good maintenance is essential for safe, economical, and trouble free operation. It will also help reduce air pollution.

To properly care for your generator, it is recommended to perform maintenance procedures on a regular basis. Other service tasks that are more difcult or require special tools are best handled by professionals and are normally performed by your small engine technician or other qualied mechanic.

If you operate your generator under unusual conditions, such as sustained high-load or high-temperature operation, or use it in dusty conditions, consult your service technician for recommendations applicable to your individual needs and use.

Improper maintenance, or failure to correct a problem before operation, can cause a malfunction which may void your warranty. Always follow the inspection and maintenance recommendations.

Remember that your service technician knows your generator best and is fully equipped to maintain and repair it. To ensure the best quality and reliability, use only new, genuine parts for repair and replacement.

Genuine factory replacement parts must be used to restore your equipment to original specications. The manufacturer will not be responsible for injuries or damages caused by use of unapproved parts and/or accessories.

WARNING

Use caution when performing maintenance. Only you can decide whether or not you should perform a given task.

6.2.1 GENERAL MAINTENANCE

On a regular basis check all nuts, bolts and screws and ensure they are all properly secured. Ensure the machine is clean free of oil and fuel spills. Inspect fuel line connections between the engine and fuel tank.

NEVER attempt to adjust or modify the factory settings of the engine or engine governor. Engine speed controls frequency portion of the electrical output (60hZ) Personal injury or damage to the engine or equipment can result if operating in speed ranges above the maximum or below the minimum allowable. Only qualied technicians with the proper equipment should to make adjustments to the engine settings.

6.2.2 ENGINE MAINTENANCE

Review the engine owners manual periodic maintenance section. Follow the recommendations for service and maintenance as outlined in your engine owners manual. Always follow the safety procedures and precautions in the owner’s manual.

6.2.3 ALTERNATOR MAINTENANCE

Review the alternator owners manual maintenance section. Follow the recommendations for service and maintenance as outlined in your alternators owners manual. Always follow the safety procedures and precautions in the owner’s manual.

6.2.4 BATTERY MAINTENANCE

Read Section 2.6 on battery safety for safe handling of the battery

Jump Starting Battery

Read Section 2.6 on battery safety for safe handling of the battery.

Caution: Battery posts,

terminals and related accessories contain lead and lead compounds, chemicals known to cause cancer and reproductive harm. Wash hands immediately after handling battery.

Remove

1. Disconnect negative (–) cable rst, then positive (+) cable.

2. Remove battery hold-down bracket and battery from unit.

Install

1. Install battery in the battery compartment

2. Connect positive (+) cable rst, then negative (–) cable.

3. Coat terminals with dielectric grease or petroleum jelly.

Cleaning the Battery

1. Disconnect negative (–) cable rst, then positive (+) cable.

2. Clean battery cable ends and terminals with wire brush. Rinse with a weak baking soda solution.

3. Connect positive (+) cable rst, then negative (–) cable.

4. Coat terminals with dielectric grease or petroleum jelly.

Charging the Battery

DO NOT fast charge. Charging at a higher rate will reduce battery life.

ALWAYS follow information provided on battery and battery charger. Contact battery manufacturer and battery charger manufacturer for detailed instructions.

1. Remove battery from unit.

2. Use a battery carrier to lift the battery or place hands at opposite corners to avoid spilling acid through the vents

3. Place battery on bench or other wellventilated area.

4. Connect positive (+) lead of charger to positive (+) terminal, and negative (–) lead to negative (–) terminal.

5. Charge battery according to the instructions from battery charger manufacturer and battery manufacturer.

WARNING:

frozen batteries can explode and result in death or serious injury. DO NOT charge a frozen battery. Let battery thaw before charging.

Unit used for jump-starting should have a 12-volt battery and a negatively grounded system.

1. Connect positive (+) jumper cable to positive terminal of discharged battery.

2. Connect the other end of the same jumper cable to positive (+) terminal of booster battery.

3. Connect one end of the second jumper cable to negative (–) terminal of booster battery.

4. Make the nal jumper cable connection to engine block or the furthest ground point away from the discharged battery.

5. Start engine.

6. After engine starts leave cables connected for one to two minutes.

7. Disconnect jumper cables in reverse order of installation.

8. Operate unit as normal to charge battery.

U1 Lawn & Garden 250 CCA

battery is not included

7 SPECIFICATIONS

Decibel Rating @7 meters (22ft)

5000

4600 R Models

6500

6700 R Models

5000

4600 R Models

6500

6700 R Models

Continuous amps (120-V)

*with full power feature on

160 CC

270 CC

389 CC

160 CC

270 CC

389 CC

4.75 US gal

6.9 US gal

4.75 US gal

6.9 US gal

Estimated run time (hours) Half load

Full load

12.5

9.1

7.2

12.5

9.1

7.2

123

Dimensions length / width / height

Inch

62.2 x 61 x 57.8

78.2 x 69.6 x 67.3

62.2 x 61 x 57.8

78.2 x 69.6 x 67.3

Full power feature

*120v continuous amps value above

is with Full Power feature on.

2 x Duplex 5-20R

1 x L5-30

2 x Duplex 5-20R

1 x L5-30

Honda Engines: Oil Alert

EPA Certified

Backup Power Series

Jobsite Rated Series

7.1 MECHANICAL

Standard Generators

Maximum watts

Continuous watts

Continuous amps (240-V)

Voltage 1

Voltage 2

Frequency

Engine

Full tank capacity

Weight lbs

Starting System

Auto idle control

Fuel

24.5 x 24 x 22.75

SHS3000

SHS3000R

68dBA 68dBA

2500

2100 4250 6250 2100 4250 6250

18.75 35.5* 52* 18.75 35.5* 52*

-- 17.75 26 -- 17.75 26

-- --

Honda GC160

18 L

16.6

145

No Yes Yes No Yes Yes

SHS5000

SHS5000R

120 120

Honda GX270

18 L

12.3

206

30.8 x 27.4 x 26.5

Pull Start Pull Start

SHS7000

SHS7000R

70.5dBA 70.5dBA

240 240

Honda GX390

26 L

12.4

271

30.8 x 27.4 x 26.5

Electric Start Electric Start

SCS3000

SCS3000R

2500

60 Hz

Honda GC160

Gasoline

18 L

16.6

145

24.5 x 24 x 22.75

SCS5000

SCS5000R

Honda GX270

26 L

12.3

206

30.8 x 27.4 x 26.5

SCS7000

SCS7000R

Honda GX390

26 L

12.4

271

30.8 x 27.4 x 26.5

No Yes* Yes* No Ye s* Yes*

Full panel GFCI protection

Automatic voltage regulation

Receptacles

Options

Details:

No No No Yes Yes Yes

WHS3000R Only WHS5000R Only WHS7000R Only W CS3000R only W CS5000R Only WCS7000R Only

1 x L5-30

G20211 • 10’ Power Cord • one male, one female • L14-30 30A Twistlock G20212 • 20’ Power Cord • one male, one female • L14-30 30A Twistlock G20213 • 25’ Power Cord • one male, one female • L14-30 30A Twistlock

All generators incorporate "neutral bonding to generator frame" safety feature. CSA Certified

1 x L14-30

1 x L5-30

SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE

1 x L14-30

7.2 BOLT TORQUE

CHECKING BOLT TORQUE

The tables shown below give correct torque values for various bolts and capscrews. Tighten all bolts to the torques specied 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

Bolt Torque*

Diameter

"A"

1/4"

5/16"

3/8"

7/16"

1/2"

9/16"

5/8" 3/4" 7/8"

METRIC TORQUE SPECIFICATIONS

SAE 2

(N.m) (lb-ft)

13 27 41 61

95 128 225 230 345

6 10 20 30 45 60 95

165 170 225

SAE 5

(N.m) (lb-ft)

12 25 45

72 110 155 215 390 570 850

Bolt Torque*

Bolt

Diameter

"A"

8.8

(N.m) (lb-ft)

19 33 53

80 115 160 290 420 630

10.9

SAE 8

(N.m) (lb-ft)

17 36

63 100 155 220 305 540 880

1320

12 27 45

75 115 165 220 400 650 970

M3 M4 M5 M6

M8 M10 M12 M14 M16 M20 M24 M30 M36

Torque gures indicated above are valid for non-greased or non-oiled threads and heads unless otherwise specied. Therefore, do not grease or oil bolts or capscrews unless otherwise specied in this manual. When using locking elements, increase torque values by 5%.

* Torque value for bolts and capscrews are identied by their head markings.

6 10 25 50 90

140 225 435

750 1495 2600

2.2 4 7

18 37

66 103 166 321 553

1103

1917

1.8

4.5

15 35

70 125 200 310 610

1050 2100 3675

1.3

3.3 7

11 26 52

148

229

450

774 1550 2710

PROBLEM CAUSE SOLUTION

Bad fuel (generator

fuel)

Low oil level caused

engine

then restart the engine

Check appliance, tool, any load connected Electrical cords

damaged

Check cord and connections for damage, replace

(3600 RPM - 60HZ)

technician

CAUTION

8 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. If you encounter a problem that is difcult 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 and serial number ready.

Fuel valve OFF Turn lever ON

Choke on Ensure choke is open

Out of fuel Refuel Ensure machine is off

Engine will not start

Breakers tripping

Erratic or No Power

120 / 240 v

stored without treating or draining

Oil Alert to stop

Fuel filter restricted Replace filter Ensure machine is off

Load connected Flip off main switch, or unplug load

Ignition malfunction, valves stuck, etc

Electrical load too high Reduce electrical load Ensure machine is off

Load or cord defective

Incorrect residential connection

GFCI

Breaker tripped

Alternator problem

Electrical cords damaged / cut

Defective capacitor Have capacitor tested and replaced

Broken / worn receptacle

Engine RPM too low

Drain fuel tank , refuel with fresh fuel Ensure machine is off

Add oil, turn engine switch to OFF and

Take the generator to an authorized servicing dealer for repair

to generator for damage, shorting

Call electrician Ensure machine is off

Some induction motors will cause GFCI to trip, switch to non GFCI receptacle

Reset breaker / GFCI, correct reason for breaker trip, replace if defective

Check connections / receptacles at control panel, inspect alternator

Check cord and connections for damage, replace

Check receptacle / GFCI for function, damage, or bad connections, replace

Have engine tuned / maintenance

Ensure machine is off

Ensure machine is off / Call technician

Ensure machine is off

Ensure machine is off / Call technician

Ensure machine is off

Ensure machine is off / Call technician

Ensure machine is off

Ensure machine is off / Call

9 ACCESSORIES

Call your dealer for pricing and availability

Generator Extention cord, the right length and size, to make the most of your generator.

• Heavy Duty SJTW Cable

• -40° cold weather jacket

• Nema L14-30P 30a 125/250v Plug

• Nema L14-30R 30a 125/250v Connector

• Water & Flame Resistant

• UL, OSHA compliant

Z63402

Z63411

G20211

Z63417

Availalbe in three sizes.

G20211 • 10’ Power Cord

G20212 • 20’ Power Cord

G20213 • 25’ Power Cord

Replacement Plugs.

Z63417 • 125/250V

• Universal Style 3 pole 4 wire

• Congure for 14-30P (30A)or 14-50P (50A)

• 4 Prong

Z63402 • 125/250V

• 30A Twistlock 3 pole 4 wire

• L14-30P

• 4 Prong

Z63411 • 125V

• 30A Twistlock 2 pole 3 wire

• L5-30P

• 3 Prong

Z93201

Z93204

U1 Style Lawn & Garden Batterys

For models:

SHS7000, SHS7000R, SCS7000 & SCS7000R.

#Z93201 U1 250CCA Lawn & Garden Battery The perfect battery to reliably get your generator started. #Z93204 U1 340CCA Lawn & Garden Battery, chose this battery for dependable starts in cold weather.

10 INDEX

ACCESSORIES ...................................................................39

AFTER OPERATING FOR 1 HOUR ....................................20

AFTER OPERATING FOR 8 HOURS ..................................20

AIR DISCHARGE ................................................................. 20

AIR INTAKE .........................................................................20

BACKFEEDING ............................................................ 12, 30

BATTERY ................................................................... 1, 6, 35

BATTERY ...................................................................... 11, 35

CAUTION ............................................................................... 7

CHARGING THE BATTERY ................................................ 35

CHOKE .................................................................................21

CIRCUIT BREAKERS .......................................................... 25

CLEANING THE BATTERY ................................................. 35

CONTINUOUS WATTAGE ...................................................26

DANGER ................................................................................ 7

ELECTRICAL COMPONENT CONDITION .........................29

ELECTRICAL HAZARD ....................................................... 29

ELECTRICAL LOADS .........................................................29

ELECTROLYTE ................................................................... 11

ELECTRONICS .................................................................... 30

EMERGENCY ......................................................................29

EMERGENCY STOPPING ...................................................29

ENGINE GOVERNOR .......................................................... 13

ENGINE OIL ......................................................................... 33

FAULT INDICATOR .......................................................25, 31

FIRST USE ............................................................................. 1

FROZEN BATTERIES ..........................................................35

FUEL ....................................................................................33

FUEL SHUT-OFF VALVE .....................................................21

FUEL TANK CAPACITY ......................................................33

G20211 .................................................................................39

G20212 ................................................................................. 39

G20213 ................................................................................. 39

HAZARDS ............................................................................ 29

IGNITION SWITCH ..............................................................21

IMPROPER MAINTENANCE ............................................... 34

INSPECTION ..........................................................................4

JUMP STARTING BATTERY ............................................... 35

LABEL INFORMATION ......................................................... 5

LOAD CALCULATION EXAMPLE ...................................... 26

LUBRICANTS ...................................................................... 33

MAXIMUM WATTAGE ......................................................... 26

NEUTRAL BONDED TO FRAME ................................... 6, 30

NOISE .................................................................................. 10

OIL ........................................................................................ 33

OIL ALERT ........................................................................... 21

OPERATING HINTS ............................................................. 25

ORIENTATION ....................................................................... 6

POP UP BREAKER ...................................................... 23, 24

REACTIVE LOAD ................................................................ 26

RESISTIVE LOAD ................................................................ 26

RESPONSIBLE ...................................................................... 8

RUNNING (CONTINUOUS) WATTAGE ............................... 26

SAFE CONDITION ............................... 9, 10, 11, 18, 28, 34

SERIAL .................................................................................. 5

SERIAL NUMBER .................................................................. 5

SIGNAL WORDS ................................................................... 7

SPECIFICATIONS ................................................................ 36

STARTING ........................................................................... 29

STARTING ROPE ................................................................ 21

STARTING WATTS .............................................................. 26

STOPPING ........................................................................... 29

TERRAIN .............................................................................. 29

THROTTLE .......................................................................... 21

TRANSPORTING .......................................................... 30, 31

WARNING .............................................................................. 7

WATTAGE CHART .............................................................. 27

WATTAGE INFORMATION .................................................. 27

WEATHER ............................................................................ 29

Z63402 ................................................................................. 39

Z63411 .................................................................................. 39

Z63417 ................................................................................. 39

Surge master SHS3000R, SCS3000, SCS5000, SCS3000R, SCS5000R Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual