shs12000 / shs12000r generator parts manualb1.parts-manual... · 4144 boomer line st. clements, ......

Surge-Master by EMB Mfg.

Rev A # 210417SHS12000 Series.Rev,10. Parts Manual.260816

Refer to the operators manual for safe operation and maintenance

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

Ph: (519) 699-9283 · Fax: (519) 699-4146www.surgemaster.ca

BY EMB MFG

SHS12000 / SHS12000RGenerator Parts Manual

Starting with S/N’sSHS12000 - 121001

SHS12000R - 122001

Surge-Master by EMB Mfg.SHS12000 Series.Rev,10. Parts Manual.260816

Rev # 210417 of 12 For threaded parts installation, refer to the torque charts in this manual.

Foreword

Surge-Master has prepared this parts manual to assist customers in ordering quality OEM replacement parts.

Proper and regular service and replacing old, worn or broken parts with the correct OEM parts are essential to prolonging the life of your Surge-Master product. Please refer to this manual before ordering any replacement parts.

All information contained in this parts manual is based on the latest product specification available at the time of printing this manual. If your product differs from the specifications contained within this manual contact Surge-Master for information.

Surge-Master reserves the right to alter specifications on their products at any time.

Reproduction of this parts manual of any kind is prohibited without prior written permission from Surge-Master.

For parts and information please contact your dealer. If your dealer is no longer available please go to our website: http://www.surgemaster.ca and click on ”PARTS INFORMATION”.



Table of ContentsBolt Torque.................................................................. 4SHS12000 / SHS12000R Main Assembly ................... 5Engine / Generator Assembly .................................. 6Frame Assembly ........................................................ 7Electrical Panel Assembly ........................................ 8Fuel Tank Assembly & Fuel Lines .............................. 9Wiring Diagram ........................................................ 10Label Layout ............................................................. 11Accessories .............................................................. 12

1 Drive End Bracket 03917001432 Fan 03920000333 Rear Bearing 6205-2RS 03903025114 Diode D2/125 25A 99103560505 Varistor 99103840056 Capacitor # :see list below

GECAP31MF Capacitor, 31.5 MFZGECAP40MF 40 MF CAPACITORGECAP14MF Capacitor, 14 MFZGECAP20MF Capacitor, 20uF

Alternator: Mecc Alte Inc. S20FS-160A

Below are alternator parts available from EMB, Mfg.For other parts and maintenance or repair information please refer to the

Mecc Alte alternator manual that shipped with the generator.

Find the value of the capacitor in your alternator, and match it to the

list shown.

Exercise extreme caution when working

with exposed wiring of the alternator,

be aware that high voltage discharge

of the capacitor is a danger.

Alternator maintenance should be performed by trained personnel only.



1/4" 8 6 12 9 17 125/16" 13 10 25 19 36 273/8" 27 20 45 33 63 457/16" 41 30 72 53 100 751/2" 61 45 110 80 155 1159/16" 95 60 155 115 220 1655/8" 128 95 215 160 305 2203/4" 225 165 390 290 540 4007/8" 230 170 570 420 880 6501" 345 225 850 630 1320 970

Bolt Torque*

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

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

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

Bolt Diamter

"A"

ENGLISH TORQUE SPECIFICATIONS

M3 0.5 0.4 1.8 1.3M4 3 2.2 4.5 3.3M5 6 4 9 7M6 10 7 15 11M8 25 18 35 26

M10 50 37 70 52M12 90 66 125 92M14 140 103 200 148M16 225 166 310 229M20 435 321 610 450M24 750 553 1050 774M30 1495 1103 2100 1550M36 2600 1917 3675 2710

BoltDiameter

"A"

Bolt Torque*8.8

(N.m) (lb-ft)10.9

(N.m) (lb-ft)

METRIC TORQUE SPECIFICATIONS

CHECKING BOLT TORQUE

The tables shown below give correct torque values for various bolts and capscrews. Tighten all bolts to the torques specified in chart unless otherwise noted. Check tightness of bolts periodically, using bolt torque chart as a guide. Replace hardware with the same strength bolt.

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

* Torque value for bolts and capscrews are identified by their head markings.

Bolt Torque



SHS1

2000

Mai

n A

ssem

bly

Batte

ries a

re no

t inclu

ded

with

gene

rator

s but

are

avail

able

for or

der,

see

your

deale

r for

detai

ls

18

11

23

15

4

1926

23

25

24

17

20

1314

922

21

1621

1

10

21

514

7

12 614

8

See E

ngine

/ Ge

nera

tor D

etail

See F

uel T

ank

Ass'y

Deta

il

See C

ontro

l Pa

nel A

ss'y

Batte

ries a

re no

t inclu

ded

with

gene

rator

s but

are

avail

able

for or

der,

see

your

deale

r for

detai

ls

18

11

23

15

4

1926

23

25

24

17

20

1314

922

21

1621

1

10

21

514

7

12 614

8

See E

ngine

/ Ge

nera

tor D

etail

See F

uel T

ank

Ass'y

Deta

il

See C

ontro

l Pa

nel A

ss'y

BOM

IDPa

rt No

.De

scrip

tion

Qty

140

66A7

02As

semb

ly, C

ontra

ctor S

eries

Pan

el1

240

67A8

03Fu

el Ta

nk A

ssem

bly1

340

67W

805

Skyh

ange

r Weld

ment

14

4067

L832

Batte

ry St

rap

15

4067

L817

1-5/1

6" O

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Gen P

late

16

4067

L824

Engin

e Mou

nt Pl

ate1

7Z6

5407

Alter

nator

, 12.0

kVA

18

Z471

67Ho

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X630

RVXE

1, Ta

per x

Rop

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Z662

16Ge

nera

tor C

ontro

l, AVR

/AI H

P - S

HS12

000R

110

Z714

12He

x Bolt

, 7/16

NC x

1-1/4

"1

11Z7

1420

Hex B

olt, 7

/16NC

x 2"

212

Z722

41He

x Loc

k Nut,

7/16

NC2

13Z7

2503

Serra

ted F

lange

Lock

nut, #

10NF

214

Z725

21Se

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Flan

ge Lo

cknu

t, 5/16

NC9

15Z7

2921

Wing

Nut,

1/4N

C2

16Z7

2956

Rive

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5/16

NC x

150

1417

Z734

32Int

- Ex

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th W

ashe

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02

18Z7

6711

Self-t

appin

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w, #1

0 x 1/

2"4

19Z7

8301

Mach

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crew,

1/4N

C x 3

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20Z7

8303

Mach

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crew,

#10N

F x 1

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21Z7

8319

Mach

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crew,

5/16

NC x

3/4" L

ockin

g15

22Z7

9933

Isolat

or, 1

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x 1" x

5/16

NC4

23Z9

3201

Batte

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0CCA

124

Z932

08Ba

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Cable

, Neg

ative

x 20

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25Z9

3209

Batte

ry Ca

ble, P

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26Z9

3403

Gard

en T

racto

r Ter

mina

l Pro

tector

- Re

d1

9Z6

6213

Gene

rator

Con

trol, A

uto-Id

le - S

HS12

000

1



34

Gask

et inc

luded

wi

th mu

ffler

41

37

31

3632

38

39

30

40

35

33

34

Gask

et inc

luded

wi

th mu

ffler

41

37

31

3632

38

39

30

40

35

33

BOM

IDPa

rt No

.De

scrip

tion

Qty

3040

67L8

38Ac

tuator

Arm

- Go

vern

or1

3140

67L8

39So

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3240

67L8

40So

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Mou

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33Z4

7167

Hond

a GX6

30RV

XE1,

Tape

r x R

ope

134

Z479

13Af

terma

rket M

uffler

, GX6

30/69

0 (Fil

ter S

ide)

135

Z656

04So

lenoid

, 10.3

lb ho

lding

force

136

Z725

03Se

rrated

Flan

ge Lo

cknu

t, #10

NF2

37Z7

7150

Hex B

olt, M

8x1.2

5 x 20

mm1

38Z7

7352

DIN

125 W

ashe

r, M8

139

Z783

03Ma

chine

Scre

w, #1

0NF

x 1/2"

240

Z793

08Do

me H

ead R

ivet, 1

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3125

241

Z654

07Al

terna

tor, 1

2kVA

1

Engi

ne /

Alte

rnat

or A

ssem

bly

Alte

rnat

or:

Mec

c A

lte In

c. S

20FS

-160

/ASe

e pa

rts c

hart

page

3Fo

r mai

nten

ance

or r

epai

r inf

orm

atio

n pl

ease

refe

r to

the

Mec

c A

lte a

ltern

ator

m

anua

l that

ship

ped

with

the

gene

rato

r.

Engi

ne:

Hon

da G

X630

RVXE

1, Ta

per x

Rop

e Fo

r mai

nten

ance

or r

epai

r inf

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n pl

ease

refe

r to

the

Hond

a En

gine

man

ual

that

ship

ped

with

the

gene

rato

r.



64

7565

6371

6171

60

67 746272

69

70

68

6673

7269

64

7565

6371

6171

60

67 746272

69

70

68

6673

7269

BOM

IDPa

rt No

.De

scrip

tion

Qty

6040

67L8

07Le

g, Lg

Fra

me R

H1

6140

67L8

07H

Leg,

Lg F

rame

LH1

6240

67W

801

Gene

rator

Stan

dard

Lg-F

rame

163

4067

W80

3Ax

le W

eldme

nt1

6440

67W

806

Weld

ment,

Han

dle Lg

.1

65Z1

2301

Cotte

r Pin,

3/32

" x 3/

4"2

66Z1

9909

Rubb

er B

umpe

r, 7/1

6" x

1"2

67Z3

4303

Sprin

g Plun

ger,

1/2" P

ress

x 1.1

" x 18

lbs

268

Z628

23Ru

bber

Gro

mmet,

5/8"

x 1/8

"1

69Z7

1217

Hex B

olt, 5

/16NC

x 1-

3/4"

270

Z722

21He

x Loc

k Nut,

5/16

NC2

71Z7

2521

Serra

ted F

lange

Lock

nut, 5

/16NC

872

Z731

22SA

E W

ashe

r, 5/1

6"4

73Z7

3223

Thick

Was

her,

5/16 x

0.12

5"2

74Z7

8319

Mach

ine S

crew,

5/16

NC x

3/4" L

ockin

g8

75Z9

1315

4.00-

6 NHS

2PR

2

Fram

e A

ssem

bly



88

86

87

8990

82

99

85

101

84

9496

81

83

103

92

9897

91

8095

93

100

102

100

99

88

86

87

8990

82

99

85

101

84

9496

81

83

103

92

9897

91

8095

93

100

102

100

99

BOM

IDPa

rt No

.De

scrip

tion

Qty

8040

66L8

04Pa

nel, H

ome S

eries

181

Z626

16Th

erma

l Bre

aker

, 15A

x TC

1 OL1

282

Z626

210

30A

- Dou

ble B

reak

er1

83Z6

2628

42A

- Dou

ble B

reak

er1

84Z6

2813

Plug

, #18

185

Z628

27Ca

ble G

land,

18-2

5mm

186

Z634

03Re

cepta

cle, L

14-3

0 x 30

A x 1

25/25

0V1

87Z6

3404

Rece

ptacle

, L5-

30 x

30A

x 125

V1

88Z6

3406

Rece

ptacle

, 5-2

0R x

20A

x 125

V2

89Z6

3409

Rece

ptacle

, 14-

50R

x 50A

x 12

5/250

V1

90Z6

3410

Rece

ptacle

, 6-5

0R x

50A

x 125

/250V

191

Z645

01Vo

ltmete

r, 0-

150V

192

Z661

12Ro

cker

Swi

tch, 2

0A S

PST

1

BOM

IDPa

rt No

.De

scrip

tion

Qty

93Z7

2111

Hex N

ut, 1/

4NC

194

Z725

02Se

rrated

Flan

ge Lo

cknu

t, #10

NC2

95Z7

2511

Serra

ted F

lange

Lock

nut, 1

/4NC

196

Z727

51Ma

chine

Nut,

#10N

C2

97Z7

3431

Int -

Ext T

ooth

Was

her,

1/4"

198

Z761

14Fla

nge B

olt, 1

/4NC

x 1"

199

Z767

11Se

lf-tap

ping S

crew,

#10 x

1/2"

410

0Z7

8304

Mach

ine S

crew,

#6NC

x 3/8

"12

101

Z783

05Ma

chine

Scre

w, #1

0NC

x 3/4"

210

2Z7

8320

SEMS

Scre

w, #6

NC x

1/4" x

Exte

rnal

Tooth

8

Z948

2312

-14k

W A

VR C

ontro

l Pan

el De

cal -

SHS1

2000

R1

103

Z948

1412

-14k

W C

ontro

l Pan

el De

cal -

SHS1

2000

1

See w

iring d

iagra

ms fo

r

wirin

g har

ness

parts

numb

ers

Elec

trica

l Pan

el A

ssem

bly



111

121 12

3

112

114

113

To E

ngine

To E

ngine

115

116

117

110

118

122119

120

111

121 12

3

112

114

113

To E

ngine

To E

ngine

115

116

117

110

118

122119

120

BOM

IDPa

rt No

.De

scrip

tion

Qty

110

Z767

14Se

lf-tap

ping S

crew,

#10 x

1/2"

Ova

l Hea

d Cou

ntersu

nk -

Blac

k Zinc

211

1Z9

3108

EPA

Ratch

et Fu

el Ca

p, Un

leade

d Fue

l x U

nven

ted w

ith T

ether

111

2Z9

3110

EPA

Remo

te Ve

nt, H

B04

111

3Z9

3111

Vent

Grom

met F

or Z

9311

01

114

Z931

18Fu

el Ga

uge,

Gene

rator

111

5Z9

3307

EPA

Fuel

Line,

1/4" x

3"1

116

Z933

20Fu

el Lin

e Clip

, 1/2"

OD

Hose

211

7Z9

3323

Fuel

Shut-

Off V

alve,

1/4" G

ener

ator

111

840

67W

802

Fuel

Tank

Weld

ment

111

940

67F8

01EP

A fue

l line

1/4"

ID x

26"

112

040

67F8

02EP

A fue

l line

1/4"

ID x

18.5"

112

140

67F8

03EP

A fue

l line

3/8"

ID x

6"1

122

Z933

08EP

A Ca

rbon

Can

ister

, 120

0cc

112

3Z9

3320

Fuel

Line C

lip, 1

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D Ho

se3

Fuel

Tank

Ass

embl

y &

Fuel

Lin

es



Wiri

ng D

iagr

am

Pan

elLE

D

QD

250

Z656

03S

olen

oid,

Red

arr

3014

2

Aut

o-Id

leS

olen

oid

30A

125V

L5-3

0ST

RP

500

ON

OFF

RIN

G#1

0

Z645

01V

oltm

eter

,0-1

50VR

ING

250

GFCI

Twist

wire

s to

geth

er w

hen

pass

ing

thro

ugh

sens

or

W B W B

ON

OFF

Line

Load

Z779

03Fl

ange

Hea

d,M

6x1.

0x

12m

m

Vie

wFa

cing

Pan

el

20A

125V

5-20

R

30A

125/

250V

L14-

30

Pop

out

Bre

aker

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A

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12-1

4kW

Wiri

ngD

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vsd

1105

15

Gro

und

toal

tern

ator

fram

e

#Z62

336

12-1

4kW

Gen

erat

orB

undl

e#Z

6234

012

-14k

WA

VR

Wire

Bun

dle

STR

P50

0

STR

P50

0ST

RP

500

SSP

#6

SSP

#6

Conn

ectio

n Ty

pe

Conn

ectio

n Id

entif

icat

ion

Size

s:#6 #8 #1

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156”

0.25

0”0.

313”

0.50

0”0.

750”

Conn

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Conn

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AV

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itor

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G#1

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125/

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ded

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pane

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ck(Y

)

#9Z6

2336

Whi

te

#2Z6

2336

Bla

ck

#3Z6

2336

Bla

ck

#4Z6

2336

Bla

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#5Z6

2336

Bla

ck

#7Z6

2336

Bla

ck

#8Z6

2336

Bla

ck

#19

Z623

36B

lack

#20

Z623

36B

lack

#21

Z623

36B

lack

#26

Z623

36B

lack

#27

Z623

36B

lack

#28

Z623

36B

lack

#29

Z623

36B

lack

#10

Z623

36W

hite

#11

Z623

36W

hite

#13

Z623

36W

hite

#14

Z623

36W

hite

#22

Z623

36W

hite

#12

Z623

36W

hite

#15

Z623

36G

reen

#16

Z623

36G

reen

#17

Z623

36G

reen

#23

Z623

36G

reen

#24

Z623

36G

reen

#31

Z623

36G

reen

#32

Z623

36G

reen

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Blu

e

# 7Z6

2340

Whi

te

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2340

Blu

e

#2Z6

2340

Blu

e

#3Z6

2340

Blu

e

#4Z6

2340

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ck

#5Z6

2340

Bla

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#8Z6

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(X)

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odel

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und

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pane

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sing

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0

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1200

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2668

Pla

in–

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28

1400

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2670

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in–

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29

Z662

16–

AV

RH

P/A

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6213

-AI

1200

0WA

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FA

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Cap

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mF

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0WA

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ap.–

40+

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FA

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Cap

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mF

Dot

ted

wire

spr

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ton

som

em

odel

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ly

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ctric

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rtZ9

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Label Layout

Z94221Z94216Z94215

!

0°

NEVER use inside a home orgarage, EVEN IF doors and

windows are open.

N'employerJAMAIS dans lamaison ou dans des secteurs

partiellement inclus tels que desgarages, MÊME SI les portes et

les fenetres soient ouvertes.

Only use OUTSIDE and faraway from windows, doors,

and vents.

Employer seulemer DEHORSet loin de fenêtres, des porte

et des ventilateurs.

DANGER!Using a generator indoors CAN KILL YOU IN MINUTES. GeneratorExhaust contains carbon monoxide. This is a poison you cannot see

or smell.

L'utilisation d'un générateur à l'intérieur PEUT VOUS FAIRE MOURIREN MINUTES. L'échappement contient le monoxyde de carbone,

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

Z94225Z94252

Z94222 Z94252

NEUTRAL BONDED TO FRAME NEUTRE RACCORDÉ AU BÂTI

120 V

AC

240 V

AC BREAKERDISJONCTEUR

IDLE CONTROLRALENTI AUTO

CIRCUIT BREAKERSINTERRUPTEUR

DE CIRCUIT

AC BREAKERDISJONCTEUR

PUSH TO RESETPRESSER POURRÉINITIALISER

Z94823

AVR

GOODOUT OF RANGEAUTO-IDLE

Z94823

Z94814 SHS12000

SHS12000R

Z94440

Z94440 Z946511

Z946510

Z94221Z94216Z94215

!

0°

NEVER use inside a home orgarage, EVEN IF doors and

windows are open.

N'employerJAMAIS dans lamaison ou dans des secteurs

partiellement inclus tels que desgarages, MÊME SI les portes et

les fenetres soient ouvertes.

Only use OUTSIDE and faraway from windows, doors,

and vents.

Employer seulemer DEHORSet loin de fenêtres, des porte

et des ventilateurs.

DANGER!Using a generator indoors CAN KILL YOU IN MINUTES. GeneratorExhaust contains carbon monoxide. This is a poison you cannot see

or smell.

L'utilisation d'un générateur à l'intérieur PEUT VOUS FAIRE MOURIREN MINUTES. L'échappement contient le monoxyde de carbone,

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

Z94225Z94252

Z94222 Z94252

Z94440

Z94440

Z946511

Z946510

Z946320

Z946321

Z946520

Z946309

Z946522

Z946523



Accessories

Call your dealer for pricing and availability

#Z93201 U1 250CCA Lawn & Garden Battery

The perfect battery to reliably get your generator started.

#Z93201

Available as a download atwww.surgemaster.ca

Availalbe in three sizes. G20211 • 10’ Power CordG20212 • 20’ Power CordG20213 • 25’ Power Cord

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

#Z97095 GENERATOR OPERATOR’S MANUAL

shs12000 / shs12000r generator parts manualb1.parts-manual... · 4144 boomer line st. clements, ......

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