SURGEMASTER SM5000LH/E/A User manual

SURGEMASTER PORTABLE GENERATORS
GASOLINE POWERED BY HONDA ENGINES
MRG102003 PRINTED IN CAN ADA
OPERATING IN STRUCTION S
AND PARTS MANUAL S
PRINTED IN CANADA
REV 102003 PART NUMBER: Z97067
EMB Manufacturing Inc.
4144 Boomer Line · St. Clements, On · N0B 2M0 · Canada
Ph: [phone] · Fax: [phone]
www.surgemaster.ca

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WARRANTY
Effective on products retailed on or after January 1, 2015.
Register your product online at www.surgemaster.ca within 30 days of purchase to activate warranty.
This product is warranted to be free of defects in materials and workmanship under normal use and service, for a period of
from the date of purchase, when operated and maintained in accordance with the Operating and Maintenance Instructions
supplied with this unit. Warranty is limited to the repair of the product and/or replacement of parts.
This warranty does not cover the following items:
1) Parts lost or damaged during shipment,
2) Normal maintenance or 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
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: [email protected]
WARRANTY IS VOID IF NOT REGISTERED
Five (5) Years for Consumer
Two (2) Year for Commercial/Rental
rev.270315

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Model SM5000LH/E/A
Engine 9 HP OHV HONDA
AC Output (watts)
- maximum 5,0 00
- rated continuous 4,5 00
Rated Amperage ( A) [120V] 37. 5/1 20V
[240V] 18. 8/2 40V
Frequency (Hz) 60
Voltage (volts) 120 /24 0
Fuel Tank Capacity (l) 22
Run time (hours)- 1/2 load 12. 5
- full load 7.2 5
Weight (lbs) 159
Dimensions (inches)
- length 27 1/2”
- width 20 1/2”
- height 28”
Oil Alert System YES
Overload protection YES
System Starting*** varies with model ELECTRIC & RECOIL
SM6000LH/E/A
11 HP OHV HONDA
6,0 00
5,5 00
41. 6
20. 8
60
120 /24 0
22
12
6.5
189
27 1/2”
20 1/2”
28”
YES
YES
ELECTRIC & RECOIL
SM7000LH/E/A
13 HP OHV HONDA
7,0 00
6,5 00
54. 1
27. 1
60
120 /24 0
22
11
6
208
27 1/2”
20 1/2”
28”
YES
YES
ELECTRIC & RECOIL
PRODUCT SPECIFICATIONS
This Surgemaster generator has been designed with ease of port ability,
quiet operation, dependability, and versatility in mind. This generator is
powered by Honda’s proven and reliabl e engine, which features Oil Alert for
enhanced operati onal reliability. The alternator features a brushless design
eliminating the need for costly carbon brush replac ement and increases the
service li fe of the generator.
Ideally suited for camping, boating, farm, househol d, workshop, and con-
struction usage, this generator is ideal when remot e or backup power is
required.
In order to determine the power requirements of the equipm ent you wish to
operate, please consult the chart on page 7. The ratings indicated are ap-
proximati ons only. You should also check the startup and running wattage
requirements of the equipment you wis h to use.
INFO RM AT ION FO R INST ALL ATION & WIRING :
NEUT RAL IS BO NDED T O FRAM E .

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Initial Setup
A. Ins tall a xle and wheels .
2. Slide wheels onto
axle shaft. Install axle
caps, then secure with
cotter pin. (shown
below).

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B. Install leg in hook, fasten with bolt.
C. Fill engine with oil. (See engine operator’s manual)

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USAGE CHART
(On Electric start model)
D. Install battery & cables. Use J-rods and flat plate to anchor battery firmly.
Red= Pos titive: Blac k= Negativ e
Generator Usage Start Watts Run Watts
Refrigerator, Freezer 2500 700
Toaster 1050
Microwave 950
Coffee Maker 1500 850
Washing Machine 2000 750
Furnace Fan 1400 700
Sump Pump 2500 600
TV 350
Circular Saw 1500 750
Drill 1000 250
Sander 1000 375

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Safety Precautions
Careful operation is your best insurance to prevent accidents and mishaps. Read
this section carefully before operating your generator. All operators, no matter how
much experience they have acquired, should familiarize themselves with the capa-
bilities of this generator and the precautions outlined in this manual.
1. To prevent electrical shocks, do not operate this generator in the rain or with wet
hands.
2. Do not refuel the engine while it is in operation or is still hot.
3. Do not refuel the engine near open ames, pilot lights, or sparking electrical de-
vices (e.g. power tools, welders, or grinders).
4. The engine should be refueled in a well-lit area.
5. Avoid fuel spillage.
6. Do not use any other fuel except gasoline (or as specied by the engine manu-
facturer).
7. Do not operate the generator near ammable products.
8. Do not operate the generator in areas with poor ventilation. The exhaust fumes
contain carbon monoxide, a poisonous, odorless, invisible gas. Prolonged expo-
sure can lead to unconsciousness and death.
9. Do not connect the generator to a commercial power line.
10. Do not operate any generator with missing or broken parts. Contact your deal-
er for replacement parts.
11. The generator should be grounded in damp or highly conductive conditions.
12. Do not operate with damaged or defective extension cords, or power cords.
Never operate any electrical equipment with damaged or defective cords.
13. Always check the engine oil level before starting. Fill as necessary refer-
ring to the Honda Engine Owners Manual for the specied engine oil.
14. Do not cover the generator while it is in operation. Overheating can result in
damaged equipment.
15. For storage, do not cover the generator until it has completely cooled down.
16. The ambient temperature should not exceed 100°F/40°C.
Before starting, read and understand all safety instructions included in this manual.

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Starting Operation
1. Locate the generator on at terrain, away from water hazards and/or
ammable liquids. Check all electrical cords for cracked or exposed wires.
Replace if necessary.
2. Follow the engine starting procedures contained in the Honda Engine
Owners Manual. Once started, allow the engine to reach operational tem-
perature for a few minutes without applying load on the alternator.
3. Make sure that the appliance is switched off before connecting it to the
generator. Do not move the generator while it is running.
4. Be sure to ground the generator if the connected appliance is grounded.
Failure to ground the generator may lead to electrical shock.
5. If the generator is overloaded, or short-circuited, a breaker switch is au-
tomatically tripped, preventing electrical current from being supplied to the
appliance. Check the appliance to ensure that the start-up wattage re.quire-
ments does not exceed the capacity of the generator. Press the reset button.
Auto Idle Operation (if equipped)
Wait until engine has reached operating temperature (approx. 5 minutes)
before using auto idle.
Auto idle feature allows engine to run at slower idle when no power is re-
quired, (i.e. cutting lumber, drilling, etc.)
It is recommended to turn auto-idle to “off” when using generator for backup
power. This will stabilize voltage.

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Shutdown Procedure
1. Turn off the power switch of the electrical appliance and disconnect from the gen-
erator.
2. Allow the engine to cool down for approximately 3 minutes at no load.
3. Refer to the Honda Engine Owner’s Manual for engine shutdown procedures.
4. Remove any mud, dirt or condensation from the generator. Store in a dry place.
Maintenance and Storage
(Please refer to the Honda Engine Owner’s Manual)
Periodic inspection and maintenance of the Honda engine are essential if a high lev-
el of performance is to be maintained. Regular maintenance will also ensure a long
service life. The required service intervals and kind of maintenance to be performed
are described and outlined in the Honda Engine Owner’s Manual.
Transportation and Storage
(Please refer to the Honda Engine Owner’s Manual)
When transporting the generator, turn the fuel valve OFF and keep the engine level
to prevent fuel spillage.
When the generator will be stored over long periods, carry out the following mainte-
nance. (Please refer to the Honda Engine Owner’s Manual)
a) Store the generator in a well-ventilated, low humidity area.
b) Clean each part with an oil-soaked rag.
c) Change the engine oil.
d) Clean the air cleaner.
e) Empty the gasoline from the fuel tank and carburetor.
f) Pull the recoil starter until resistance is felt, leaving the handle in that position.
Caution: Never use water to clean the generator.

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POSITION DESCRIPTION QUANT ITY SM5000
CO MPL E T E A L TER NA TOR 1G25200
2ENDCA P 1G25051
7 NO N DRIV E END B RA CK ET 1 G25048
8 STA TOR 1 G25034
9 DRIV E END B RA CK ET 1 G25035
14 ROTOR ASSEMBLY 1 G25036
15 FA N 1 G25037
19 REAR BEARING 1 G25038
26 DIODE 1 G25039
27 VARISTOR 1 G25040
28 SECURING S T UD 4 G25042
29 STUD 1 G25043
65 CAPACITOR 1 G25044
67 ENCLOS ING BA ND 1 G25046
68 INTERCHA N G EA BLE FLA NG E 1 G25047
107 RUBB ER CA P 1 G25028
ALTERNATOR BREAKDOWN
SM5000

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POSITION DESCRIPTION QUANTITY PART #
1 GRID 1 G20091
2 TERMINAL BOX LID 1 G20092
5 TERMINA L BOA RD 1 G20093
8 FRA ME A ND STA TO R 1 ***
9 DRIV E END B RA CK ET 1 ***
14 ROTOR ASSEMBLY 1 G20094
15 FA N 1 G20095
17 DR IV E EN D B EA R I NG 1 G20096
19 NON DRIVE END BEARING 1 G20097
26 DIODE 2 G20098
27 VARISTOR 2 G20099
29 SECURING S T UD 1 G20106
39 PRO T EC TIO N S CREEN 1 G20101
40 FIXING RING 1 G20102
65 CAPACITOR 1 G20103
75 RUBBER CUP 1 G20104
107 SECURING S T UD CUP 1 G20105
CO MPL ET E A LTERNA TOR UNIT 1 G20100
ALTERNATOR BREAKDOWN
SM6000 & SM7000 SERIES

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1 6
27
3 8
4 9
5
POSITION DESCRIPTION QUANTITY
HONDA ENGINE 1 GX27 0
1 FUEL TANK 1 G50 134
2 FUEL FILTER 1 G50 122
3 FUEL TANK CA P 1 G20 118
4RUBBER MOUNT 4G20 041
FRONT ENGINE MOUNT BRACKET 1 G50 135
5 FRAME 1 G50 118
6FACE PL ATE (LH SERIE S) 1G50 131
7 20A DUP LEX RECEPT ACLE 2 G20 017
8 20A POP OUT BREA KER 2 G25 014
9 30A, 1 25/ 25 0V T WIST LOCK R ECE PT ACLE 1 G20 012
AUTO IDLE SOLENOID 1 G20 124
AUTO IDLE MODULE 1 G50 137
AUTO IDLE SW ITCH 1 G50 136
FACE PL ATE (LHE SERI ES) G50 132
FACE PL ATE (LHA E S ERIES) G50 133
PARTS LIST– SM5000/6000/7000LH/E/A

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Information for your records.
Date of purchase:___________________________________________
Selling Dealer: _____________________________________________
Generator Model: ___________________________________________
Serial Number: ______________________________________________
Trouble Cause Remedy
Alternator excitation Low speed. Check rpm and set at nominal v alue
f ailure Faulty condenser Check and replace
Faulty windings Check windings resistance
High no-load v oltage Speed too high Check and adjust rpm
Condenser with Check and replace
high capacity
Low no-load v oltage Speed too low Check and adjust rpm
Faulty rotary diodes Check and replace
Breakdo wn in Check winding resistance, as per
windings tables
Condenser with Check and replace
low capacity
Proper no-lo ad but Low loaded speed Check and regulate rpm
low loade d v oltage Load too big Check and change
Rotary diodes Check and replace
short-circuited
Proper no-lo ad but High speed in Check and regulate rpm
high loaded v oltage load condition
Unstable v oltage Loose contacts Check connections
Unev en rotation Check f or unif orm rotation speed
Noisy generator Broken bearings Replace
Poor coupling Check and repair
Troubleshooting
The majority of problems with generator units are with the engine. Please
refer to the Honda Engine Owner's Manual if engine problems arise. If the
problem persists, contact your local Honda Equipment Dealer.