Surge master SM3000SU, SM3000GFI, SM5000GFI, SM2500CH, SM3000CH Operator's Manual

BY EMB MFG INC.

EMB Manufacturing Inc.

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

Ph: [phone] · Fax: [phone]

www.surgemaster.ca

PORTABLE GENERATORS

OPERATOR'S MANUAL

SM3000SU

SM2500CH

SM2500CH
SM3000CH
SM5000CH

Before putting the generator into service:

Do not attempt to start or operate the generator without
thoroughly reviewing this manual for safe and proper operation.

SM3000GFI

SM3000CH

SM5000GFI

SM5000CH

SM3000SU
SM3000GFI
SM5000GFI

Keep this manual with the Generator at all times

PRINTED IN CANADA
REV 0160714 PART NUMBER: Z97037

PS

C

CERTIFIED.

ELECTRICAL SAFETY

®

US

TABLE OF CONTENTS

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

SURGEMASTER ........................................................ 4

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

LABELLING 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 .........................................11

2.5 MAINTENANCE SAFETY ........................ 12

2.6 REFUELING SAFETY ............................. 12

2.7 OPERATING SAFETY ............................. 13

2.8 TRANSPORT SAFETY ............................ 14

2.9 STORAGE SAFETY................................. 14

2.10 ELECTRICAL SAFETY ............................ 14

2.11 GAS MOTOR SAFETY ............................ 15

2.12 SIGN-OFF FORM .................................... 16

3 SAFETY SIGNS .......................................... 17

3.1 HOW TO INSTALL SAFETY SIGNS: ....... 17

3.2 SAFETY SIGN EXPLANATIONS: ............ 17

4 OPERATION & FEATURES ....................... 19

4.1 TO THE NEW OPERATOR OR OWNER 19

4.1.1 SAFE CONDITION ................................. 19

4.2 MACHINE COMPONENTS ...................... 20

4.3 MACHINE BREAK-IN .............................. 21

4.4 PREOPERATION CHECKLIST................ 21

4.5 CONTROLS ............................................. 22

4.5.1 ENGINE CONTROLS .............................. 22

4.5.2 ELECTRICAL PANEL............................... 23

SM2500CH & SM300CH ..................... 23

SM3000SU & SM3000GFI .................. 23

SM5000GFI ........................................ 23

SM5000CH .......................................... 23

CIRCUIT BREAKERS:......................... 24

GFCI OUTLETS: ................................. 24

OPERATING HINTS: ........................... 24

4.6 ELECTRICAL LOAD ............................... 25

4.6.1 BALANCING LOADS ............................... 25

4.6.2 WATTAGE AND LOAD .........................25

REACTIVE LOAD ............................25

RESISTIVE LOAD ...........................25

CONTINUOUS WATTAGE ..............25

MAXIMUM WATTAGE .....................25

4.6.3 CALCULATING LOAD .........................25

4.6.4 WATTAGE CHART ...............................26

5 FIELD OPERATION ................................ 27

5.1 PREPARE ............................................27

5.2 START ..................................................28

5.2.1 STARTING THE GENERATOR:...........28

5.2.2 STOPPING: .........................................28

5.2.3 EMERGENCY STOPPING: .................28

5.2.4 TERRAIN: ...........................................28

5.2.5 WEATHER: ..........................................28

5.2.6 ELECTRICAL LOADS: .........................28

5.2.7 COMPONENT CONDITION: ...............28

5.2.8 ELECTRICAL HAZARDS: ....................28

5.3 RESIDENTIAL......................................29

5.4 MOVING ..............................................29

5.4.1 TRANSPORTING: ...............................29

5.4.2 WHEEL KIT: ......................................... 29

5.5 STORAGE ...........................................30

5.5.1 PLACING IN STORAGE ......................30

5.5.2 REMOVING FROM STORAGE ...........30

6 SERVICE AND MAINTENANCE ............31

6.1 SERVICE .............................................31

6.1.1 FLUIDS AND LUBRICANTS ................31

6.1.2 FLUIDS AND LUBRICANTS ................31

6.2 MAINTENANCE ...................................32

6.2.1 GENERAL MAINTENANCE .................32

6.2.2 ENGINE MAINTENANCE ....................32

6.2.3 ALTERNATOR MAINTENANCE ..........32

7 SPECIFICATIONS ..................................33

7.1 MECHANICAL......................................33

7.2 BOLT TORQUE .................................... 34

8 TROUBLE SHOOTING ...........................35

9 ACCESSORIES ......................................36

2

WARRANTY

WARRANTY

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

Register your product online at

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

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

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

This warranty does not cover the following items:

1) Parts lost or damaged during shipment,

2) Normal maintenance or 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

www.surgemaster.ca within 30 days of purchase to activate warranty.

Three (3) Years for Consumer

One (1) Year for Commercial/Rental

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

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

the maintenance of the product.

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

anyone other than an authorized service centre.

If a 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

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

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

for your 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: [phone] Fax: [phone] : attention to Warranty Dept

Email: [e-mail]

rev.091111

3

WARRANTY IS VOID IF NOT REGISTERED

SurgeMaster

Portable Diesel Generator

Check Electrical Connections

Check Function of Generator

Check that Fasteners are Tight

Check Engine Fluid Levels

Review Operating and Safety Instructions

Safety Checks

All Safety Decals Installed

Guards and Shields Installed and Secured

Test GFCI oulets

Review Operating and Safety Instructions

Emergency Power Series: SM2500CH, SM3000CH, SM5000CH

Contractor Ready Series SM3000SU, SM3000GFI, SM5000GFI

DELIVERY INSPECTION REPORT

To activate warranty, register your product online at

www.surgemaster.ca

_________________________________________
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

4

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 Location

SERIAL NUMBER LOCATION

Emergency Power Series or Contractor ReadySeries Portable Gas Generator

Model Number ____________________________________________________

Serial Number ____________________________________________________

LABELLING 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 and always with a yellow back­ground colour 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).

Informative Labels are generally pictorial, have a white back­ground colour 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)

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.surgemaster.ca.

safety alert

message

safety label

5

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

in case of power outage,
arises. The emergency 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 Contractor Ready Series generator
the 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,
and dependable source of power,

the pull start gas powered engines produce a steady

for all your power tools.
the neutral conductor bonded to the frame, Contractor Ready 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.

Optional Kits: available are the WK210 & WK214 Wheel Kits, which make it a one person job to easily

move your generator into position.

Use the Table of Contents or Index as a guide to locate required information. Keep this manual handy for
frequent reference and to pass on to new operators or owners. Call your Wallenstein 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.

or when the need

are designed with

As well having

SM2500CH

6

SM3000SU

SM3000CH

SM3000 GFI

SM5000CH &

SM5000 GFI

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
Wallenstein 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.

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.

If you have any questions not answered in this manual or require additional copies or the manual is dam­aged, please contact your dealer or Wallenstein, 4144 Boomer Line, St. Clements, ON, N0B 2M0. Phone
[phone] or Fax [phone].

7

SAFETY

YOU are responsible for the SAFE operation and

maintenance of your Wallenstein 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 opera-

tor is not qualied 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 modication 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!

8

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.

9

2.3 SAFETY TRAINING

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.

10

2.4 PREPARATION

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 al-

low 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 full-time
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.

Caution: Hearing loss from
loud noise (from tractors,

chain saws, radios, and
other such sources close to the
ear) is cumulative over a lifetime
without hope of natural recovery.

11

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 extin-

guisher (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 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.

12

2.7 OPERATING SAFETY

Z94216

Z94222

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

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

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

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 operate near openings to
any building that can be occu­pied in order to help avoid the
exhaust hazard.

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.

13

Z94221

2.8 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.

2.10 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.

2.9 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.

14

2.11 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 wit 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.

15

2.12 SIGN-OFF FORM

Wallenstein 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

16

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.

Caution: 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.

17

3 SAFETY SIGN LOCATIONS

DANGER!

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!

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 à l'intérieur PEUT VOUS FAIRE MOURIR

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

Ceci est un toxique que vous ne pouvez ni voir ni sentir.

or smell.

Z94901

NEVER use inside a home or

garage, EVEN IF doors and

windows are open.

94221

N'employerJAMAIS dans la

maison ou dans des secteurs
partiellement inclus tels que des
garages, MÊME SI les portes et

les fenetres soient ouvertes.

NEUTRAL BONDED TO FRAME

NEUTRE RACCORDÉ AU BÂTI

GENERATOR MUST BE USED IN SHELTERED OUTDOOR USE ONLY

CETTE GÉNÉRATRICE DOIT ÊTRE UTILISÉ SOUS UN

ABRI EXTÉRIEUR AU SEC SEULEMENT

94222

Only use OUTSIDE and far
away from windows, doors,

Employer seulemer DEHORS

et loin de fenêtres, des porte

et des ventilateurs.

and vents.

94225

Z94901

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.

18

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.

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

19

to use the Generator safely and how to set it to

provide maximum eld efciency. By following

the using 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

cc

Alternator

kVA

Continuous

wattage

Maximum

wattage

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

SM2500CH 160cc 2.9 kVA 2100 2500

SM3000CH 160cc 2.9 kVA 2700 3000

SM5000CH 270cc 4.9 kVA 4500 5000

SM3000SU 169cc 2.9 kVA 2500 3000

SM3000GFI 160cc 2.9 kVA 2700 3000

SM5000GFI 270cc 4.9 kVA 4500 5000

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

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

using portable electrical equipment on job sites.

The unit is designed to provide electrical power for
work (Contractor Ready series) or home (Emer­gency 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.

Note:

Alternator

Circuit

Breaker

Outlets

Engine

see "Controls" sec-

tion and engine own-

ers manual for more

engine information

Frame

20

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:

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 (if in­stalled) .

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.

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.

P

Air Discharge

Air Intake

Ensure alternator openings

are free and unblocked

21

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.

1. Ignition Switch: This switch controls the elec­tric power to the engine.

Fuel

Tank

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: This push/pull ring (GC160) slide

lever (GX160 &270) 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.

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

5. Fuel Shut-Off Valve: (EX17, GX160
& GX270 only) 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.

Fuel
Tank

Choke

Fuel

Shut-off

Choke

Starting

Rope

SM2500CH - GC160

Fuel

Tank

On / Off

Starting

Rope

SM3000CH & SM3000GFI - GX160

Choke

Fuel

Shut-off

Starting

Rope

SM3000SU - EX170

22

On / Off

Fuel

Tank

Choke

On / Off

Fuel

Shut-off

Starting

Rope

SM5000CH & SM5000GFI - GX270

4.5.2 ELECTRICAL PANEL

SM2500CH

Two duplex receptacles provide 120v, protected
by one 20 amp pop up breaker.

20 amp pop

up breaker

2 x 125v 20 amp

duplex receptacles

(5-20R)

SM3000CH

Two duplex receptacles provide 120v, each pro­tected by a 20 amp pop up breaker.

SM3000SU & SM3000GFI

Two duplex GFCI outlets provide 120 v, each
protected by a 20 Amp pop up breaker.

SM5000GFI

Two GFCI duplex receptacles for 120v power,
each protected by a 20 amp pop up breaker.

2 x 20 amp pop

up breaker

2 x 125v 20 amp

duplex receptacles

(5-20R)

2 x 20 amp pop

up breaker

2 x 125v 20 amp

GFCI duplex

receptacles

(GFCI 5-20R)

2 x 20 amp pop

up breaker

SM5000CH

One four prong twist lock outlet is used to provide
120/240 Volt, protected by two 20 amp pop up break­ers. One split duplex outlet for 120v, protected by a
20 Amp pop up breaker for each outlet .

23

2 x 125v 20 amp

GFCI duplex

receptacles

(GFCI 5-20R)

125/250v L14-30R

receptacle

(20 amp max.)

2 x 20 amp pop

up breaker

125v 20 amp

duplex receptacle

(5-20R)

CIRCUIT BREAKERS:

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.

• If a breaker trips,:

• the breaker reset pops out

• switch off or disconnect the load, deter­mine the source of the over load and
correct,

• allow the breaker to cool,

• depress the breaker button to reset,

• turn on or reconnect the load

Circuit Breaker

GFCI

GFCI OUTLETS:

GFCI outlets main purpose is to protect people
from electric shock. GFCI equipped outlets

monitor the amount of current owing from hot

to neutral. If there is any imbalance, it trips
the circuit. It is able to detect an imbalance
as small as 4 or 5 milliamps, and it can react
almost instantly to trip the circuit.
If the GFCI trips:

• reset button pops out, indicator lights up.

• switch off or disconnect the load,

• determine the source of the imbalance
and correct,

• depress the extended GFCI button to
reset,

• turn on or reconnect the load.

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 (39° C) to prevent overheating.

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

Fault Indicator

Reset Button

IMPORTANT

A circuit breaker that trips

repeatedly indicates a

problem.

Generator in optimum

working conditions

24

4.6 ELECTRICAL LOAD

below maximum

Starting

Watts

Running

Watts

Load Calculation Example

4.6.1 BALANCING LOADS

Balancing loads section applies to model
SM5000CH (120v/240v.)

When operating your SurgeMaster generator
please be aware of load balancing when using
120v receptacles.

The alternator powers two legs of 120v each

(series). Each leg supplies half the amps, specic

to receptacles on each leg (one leg to each 120v
receptacle and both legs to 240v receptacle).

240V will balance automatically since both legs
are connected to the same load. (unless the load
is split further down the line)

Since 120v legs are independent of each other
they can be loaded differently and become unbal-

anced. Signicantly unbalanced loads will cause

one leg of the alternator to heat up more than the
other causing uneven wear in the alternator and
can lead to eventual failure.

Before connecting loads to the generator, nd

the amperage draw of each load and combine
and distribute the loads so that they are bal­anced across all receptacles. Balancing can be
achieved, for example, by spreading multiple
loads over 2 receptacles rather than running all
loads from one receptacle.

When the generator supplies 120v exclusively,
then both legs share the load (parallel) and there
is no need to balance the load.

Make sure the accumulated wattage rating of
tools or appliances does not exceed that of the
generator.

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.

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.

4.6.3 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

1

Refrigerator/Freezer 1200 192

load calculation ex-

1

Furnace Fan (1/8 hp) 500 300

ample

6

Lighting (40w ea) 240 240

Totals

1940 732

4.6.2 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)

25

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

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

wattage combination
chart

OK

OK

Stop

Stop

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

26

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 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.

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)

27

• 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

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

• 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.)

• 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.

5.2.6 ELECTRICAL LOADS:

The generator is ideally suited to camping,
boating, 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.

5.2.5 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.

28

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.

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 WHEEL KIT:

A wheel kit is available to make movement

around the work area easier. Kit consist of han­dles and axle with tires The kit is easy to install
and simply clamps on to the existing frame.
Available with 10" tires (WK210) or 14" tires
(WK214)

29

Wheel Kit

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, appli-

ance 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)

30

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:
SM2500CH 3.1 L (3.3 US qt)
SM3000SU 3.6 L (1.0 US gal)
SM3000GFI 3.1 L (3.3 US qt)
SM3000CH 3.1 L (3.3 US qt)
SM5000CH 5.3 L (1.4 US gal)
SM5000GFI 5.3 L (1.4 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.

6.1.2 FLUIDS AND LUBRICANTS

Use the Maintenance Checklist provided to keep a
record of all scheduled maintenance.

1. Use a hand-held grease gun for all greasing.

2. Wipe grease tting with a clean cloth before

greasing, to avoid injecting dirt and grit.

3. Replace and repair broken ttings immedi-

ately.

4. If ttings will not take grease, remove and

clean thoroughly. Also clean lubricant pas-

sageway. Replace ttings if necessary.

31

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.

Use caution when performing

decide whether or not you should

DANGER

maintenance. Only you can

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.

32

7 SPECIFICATIONS

Maximum watts

2500 3000 5000 3000 3000 5000

Continuous watts

2100 2700 4500 2500 2700 4500

Maximum amps (120-V)

Continuous amps (120-V)

19 25 37.5 25 25 37.5

Maximum amps (240-V)

-- -- 21 -- -- --

Continuous amps (240-V)

-- -- 18.8 -- -- --

Voltage 1

120 120 120 120 120 120

Voltage 2

-- -- 240 -- -- --

Frequency

Honda GC160

160 CC

Honda GX160

160 CC

Honda GX270

270 CC

Subaru EX170

169 CC

Honda GX160

160 CC

Honda GX270

270 CC

3.3 US qt

3.3 US qt

1.4 US gal

3.8 US qt

3.3 US qt

1.4 US gal

Estimated Run time (hours) Half load

Full load

3

2.5

4
2

4
3

4
3

4
3

4
3

Weight kg

lbs

68

150

85

187.4

122
269

68

150

85

187.5

122
269

Starting System

Warranty Residential / Comm ercial

1 x Duplex 5-20R

Emergercy Power Series

Contractor Ready Series

Subaru:

7.1 MECHANICAL

Economy Generators

Preset Engine RPM (60Hz)

Full tank capacity

Dimensions length / width / height Inchcm22”x16”x16”

Receptacles

SM2500CH SM3000CH SM5000CH SM3000SU SM3000GFI SM5000GFI

Engine

Fuel

55.8 x 40.6 x 40.6

WK210 10" Wheel Kit
WK214 14" Wheel Kit

G20211 • 10’ Power Cord • one male, one female • L14-30 30A Twistlock

Options

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

Honda Engines: Oil Alert

Details:

SM5000CH & SM5000GFI feature lift / security hook.
All SurgeMaster generators incorporate "neutral bonding to generator fram e" safety feature.

21.6 27.5 41.5 27.5 27.5 41.5

60 Hz

3600 RPM

3.1 L

Low Oil Shut Off

3.1 L

22”x16”x16”

55.8 x 40.6 x 40.5

5.3 L

25.5”x20”x21”

64.7 x 50.8 x 53.4

1 x L14-30

Gasoline

22”x16”x16”

55.8 x 40.6 x 40.6

pull start

3 YR

3.6 L

3.1 L

22”x16”x16”

55.8 x 40.6 x 40.6

2 x GFCI Duplex 5-20R2 x Duplex 5-20R

25.5”x20”x21”

64.7 x 50.8 x 53.4

5.3 L

SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE

33

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"

1"

METRIC TORQUE SPECIFICATIONS

SAE 2

(N.m) (lb-ft)

8
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)

(N.m) (lb-ft)

9
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.

.5

3

6
10
25
50
90

140
225
435

750
1495
2600

.4

2.2
4
7

18
37

66
103
166
321
553

1103
1917

1.8

4.5
9

15
35

70
125
200
310
610

1050
2100
3675

1.3

3.3
7

11
26
52

92
148
229
450
774

1550
2710

34

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

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

35

9 ACCESSORIES

Call your dealer for pricing and availability

#WK210
Shown mounted
on SM3000GFI

#WK210 TWO WHEEL KIT WITH 10'' TIRES
#WK214 TWO WHEEL KIT WITH 14'' TIRES

For all models: A must have add on kit for true
portability!

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

#G20211

Z63402

Z63411

Z63417

Availalbe in three sizes.

G20211 • 10’ Power Cord

G20212 • 20’ Power Cord

G20213 • 25’ Power Cord

For SM5000CH

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

36

9 INDEX

Symbols

5-20R .................................................................................... 23

A

ACCESSORIES ...................................................................36

AFTER OPERATING FOR 1 HOUR ....................................21

AFTER OPERATING FOR 8 HOURS ..................................21

AIR DISCHARGE ................................................................. 21

AIR INTAKE .........................................................................21

B

BACKFEEDING ............................................................ 13, 29

C

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

CHOKE .................................................................................22

CIRCUIT BREAKERS .......................................................... 24

CONTINUOUS WATTAGE ...................................................25

D

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

E

ELECTRICAL COMPONENT CONDITION .........................28

ELECTRICAL HAZARD ....................................................... 28

ELECTRICAL LOADS .........................................................28

EMERGENCY ......................................................................28

EMERGENCY STOPPING ...................................................28

ENGINE GOVERNOR .......................................................... 14

ENGINE OIL ......................................................................... 31

F

FAULT INDICATOR ..............................................................24

FUEL ....................................................................................31

FUEL SHUT-OFF VALVE .....................................................22

FUEL TANK CAPACITY ......................................................31

G

G20211 .................................................................................36

G20212 ................................................................................. 36

G20213 ................................................................................. 36

GFCI ..................................................................................... 24

GFCI 5-20R .......................................................................... 23

H

HAZARDS ............................................................................ 28

I

IGNITION SWITCH ..............................................................22

IMPROPER MAINTENANCE ............................................... 32

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

L

L14-30R ................................................................................23

LABELING ............................................................................. 5

LABELLING INFORMATION .................................................5

LUBRICANTS ...................................................................... 31

M

MAXIMUM WATTAGE .........................................................25

N

NEUTRAL BONDED TO FRAME ................................... 6, 29

NOISE .................................................................................. 11

O

OIL ........................................................................................31

OIL ALERT ........................................................................... 22

OPERATING HINTS .............................................................24

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

OSHA ...................................................................................20

P

POP UP BREAKER .............................................................23

R

REACTIVE LOAD ................................................................ 25

RESISTIVE LOAD ................................................................25

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

RUNNING (CONTINUOUS) WATTAGE ...............................25

S

SAFE CONDITION ............................... 9, 10, 12, 19, 27, 32

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

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

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

SPECIFICATIONS ................................................................33

STARTING ...........................................................................28

STARTING ROPE ................................................................22

STARTING WATTS ..............................................................25

STOPPING ........................................................................... 28

T

TERRAIN ..............................................................................28

THROTTLE ..........................................................................22

TRANSPORTING ................................................................. 29

W

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

WATTAGE CHART ..............................................................26

WATTAGE COMBINATION CHART .................................... 25

WATTAGE INFORMATION .................................................. 26

WEATHER ............................................................................28

WHEEL KIT .......................................................................... 29

WK210 ........................................................................... 29, 36

WK213 ..................................................................................29

WK214 ........................................................................... 29, 36

Z

Z63402 .................................................................................36

Z63411 ..................................................................................36

Z63417 .................................................................................36

37