HGI Generators SKD100-I User manual

Ravenstor Road
Wirksworth
Derbyshire
DE4 4FY
ENGLAND
Sales Tel: [phone]
Sales Fax: [phone]
Email: [email protected]
[email protected]
Website: www.hgigenerators.com
Operation and Maintenance Manual
10.0 kVA Diesel Generator
Build No: SKD100-I, SKD100-IR
Publication No 498-1060
© Harrington Generators International Limited
All rights reserved. No part of this publication may be reproduced in any material form (including photography or storing in
any medium by electronic means or other) without the written permission of the copyright holder except in accordance with
the provisions of the Copyright, Designs and Patents Act 1988.
Applications for the copyright holder’s written permission to reproduce any part of this publication should be addressed to
Harrington Generators International Limited at the address above.
Any reference to trademarked product names used within this publication is owned by their respective companies.
Harrington Generators International Limited reserves the right to change the contents of this document without prior notice.

Machine specications can be modied at any time without any obligation to update
this publication. It is recommended to read this manual thoroughly because incorrect
operation may result in the warranty being void. Therefore it is also recommended to use
only original manufacturer spare parts.
Reproduction of this manual is not permitted, unless written approval is obtained
from the manufacturer.
Change Control
Date Version Author Reason for change
Jan 16 Provisional MC Draft for Review by Andrew Palmer, Paul
Dobbing, Dan Clay
Jan 16 A MC Updated following review and released
Jan 16 B MC Updated cover image
Mar 16 C MC Updated to include AMF/Remote start
functionality and Installation commentary
Jun 16 D LMG Updated to clarify return to idle operation
Jan 17 E MC Upd Warranty Iss H

SKD100-I
3000 RPM
Diesel Generator

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SKD100
01. REFERENCE GUIDE ...............................................................................page..6
02. ACCIDENT PREVENTION / SAFETY REGULATIONS ...........................page..9
03. ENVIRONMENTAL DIRECTIONS ...........................................................page.16
04. THE POWER GENERATOR .....................................................................page.18
05. TECHNICAL DATA ..................................................................................page.23
06. INSTALLING AND STARTING THE POWER GENERATOR ..................page.27
07. USING THE GENERATOR ......................................................................page.31
08. MOVING THE GENERATOR ...................................................................page.35
09. GENERATOR MAINTENANCE ..............................................................page.37
OIL
11. SPARE PARTS ........................................................................................page.46
12. ELECTRICAL DIAGRAM ........................................................................page.52
10.OPTIONAL ACCESSORIES ...................................................................page.42
TABLE OF CONTENTS
13. WARRANTY.............................................................................................page.56

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01. REFERENCE GUIDE
01.1- This publication....................................................................................................................page.7
01.2- Purpose................................................................................................................................page.7
01.3- Reference to regulations......................................................................................................page.7
01.4- Using this manual.................................................................................................................page.8
01.5- Terminology..........................................................................................................................page.8
01.6- Abbreviations........................................................................................................................page.8

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01. REFERENCE GUIDE
01.1 THIS PUBLICATION
The “USE AND MAINTENANCE MANUAL”, published by
the manufacturer, is an integral part of the power gen-
erator. The manual is identied by a publication identi-
er, printed on the cover page and repeated at the foot
of every page, which allows the reader to identify and
locate the publication and/or make subsequent reference
to it.
All the information included herein is brought up to the
date of publishing. The manufacturer reserves the right
to modify it without notice, and accepts no responsibility
for any error and/or omission.
01.2 PURPOSE
The USE AND MAINTENANCE MANUAL is intended for
users and holds all the information necessary for using
the product and perform its regular maintenance. Good
working conditions, long life of the power generator, and
the protection and safety of users, will be dependent
upon strict observance of the instructions included in this
manual.
It is advisable to read thoroughly and observe the direc-
tions included in this publication, which are organised, as
far as possible, according to the chronological sequence
of operations when approaching the unit.
01.3 REFERENCE TO REGULATIONS
This manual has been produced according to the
regulations provided by:
• Attachment “I” to 2006/42/CE 98/37/EC Direc-
tive and subsequent amendments (paragraphs
“b”, “c” of article 1.1.2 and article 1.7.4);
• UNI EN 292/2 - 1992, article 5.5.
This generator is complying with the provisions of
the following directives:
2006/42/EC: Machine Directive (former 98/37/EC);
89/336/EC, 93/68/EC: Electromagnetic
Compatibility Directive;
• 73/23/EC: Low Voltage Directive;
• 2000/14/EC: Noise Emission in the Environment
Directive.
SOME NOTES ABOUT NOISE EMISSION
(2000/14/EC Directive)
Sound power level (LWA):
Indicates the level of noise as required by the Eu-
ropean Directive. It represents the amount of sound
energy emitted in the time unit and is a characteris-
tic of the sound source independent of the distance
from the point of measurement. dB(A) is the unit of
measurement.
Sound pressure (Lp):
Measurement of the pressure generated by the emis-
sion of sound waves taken at a certain distance from
the source. Its value changes with the distance from the
source and is also measured in dB(A).
WARNING! Special attention must be paid to avoiding
confusion between LWA and Lp. In this manual the noise
emission is indicated as sound power level (LWA) and
sound pressure (Lp) as well. Sound pressure values (Lp),
as a function of distance, can be calculated for equip-
ment with a given sound power level (LWA) using the
following table:
Lp at 1 m = LWA -8 dB
Lp at 4 m = LWA -20 dB
Lp at 7 m = LWA -25 dB
Lp at 10 m = LWA -28 dB
Lp at 16 m = LWA -32 dB
Example: for equipment with LWA = 90 dB:
Lp at 1 m = 90 dB - 8 dB = 82 dB
Lp at 4 m = 90 dB - 20 dB = 70 dB
Lp at 7 m = 90 dB - 25 dB = 65 dB
Lp at 10 m = 90 dB - 28 dB = 62 dB
Lp at 16 m = 90 dB - 32 dB = 58 dB
The Directive 2000/14/EC species that the limits
of sound emissions are dependent on the power
output of power generators or welding generators.
The limits set down by this Directive are relating to
the sound power level guaranteed and not to the
sound power level measured, which does not take
account of all the possible variables resulting from
either the production stage or the different measure-
ment procedures.
The reduction of the limits provided for has been
divided in two phases: the rst phase in force
from 03/01/02 and the second phase in force from
03/01/06. The following table shows the sound
power levels (LWA) approved for power generators
and welding generators.
The Directive 2000/14/EC requires that the power
generator or welding generator is marked with the
sound power level guaranteed and the CE Marking
relating to the EC Declaration of Conformity.
The marking of the sound power level
guaranteed consists of a number in dB,
the LWA mark and the specic symbol:
Reference Guide

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01. REFERENCE GUIDE
01.6 ABBREVIATIONS
01.4 USING THIS MANUAL
“Symbols” are used along with text to highlight and
point out visually the relevance of different types of
information.
Graphic representation of symbols and their meaning:
Points out to important complementary informa-
tion.
The non-observance of associated directions
can cause damage, even irreparable, to the
power generator.
Points out to possible situations dangerous for
people.
This manual, together with appendices and any
inclusions, must be kept with the utmost care and always
be unabridged, undamaged and readable in its entirety.
If lost, a copy must be promptly requested to the manu-
facturer.
01.5 TERMINOLOGY
Explanation of some of the terms relating to the power
generator and used in this publication.
FRONT: the part of the unit where the control panel
is located.
BACK: the opposite part.
RIGHT OR LEFT SIDE: referred to an operator standing
in front of the unit and looking at the control panel.
A ampere
V volt
ca alternate current
cc direct current
3F + N three phase plus neutral
Ah ampere / hour
Hz hertz
hp horsepower (1hp = 0,736 kW)
cos ϕ power factor
kW kilowatt
kWm kilowatt motor
kVA kilovolt ampere
kg kilogram
l litre
l/h litre / hour
mm millimetre
m metre
s second
°C degree Celsius
LWA sound power level
Lp sound pressure
dB(A) decibel

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02. ACCIDENT PREVENTION / SAFETY REGULATIONS
02.1- Precautions to be observed...................................................................................................page.10
02.2- Risks for the operator when using this unit............................................................................page.11
02.3- Protective clothing recommended for operators....................................................................page.11
02.4- Meaning of safety signs.........................................................................................................page.12
02.5- Location of safety signs provided on the unit........................................................................page.15

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02. ACCIDENT PREVENTION / SAFETY REGULATIONS
Read carefully the instructions for use; operate according
to the regulations in force in your country.
02.1 SAFETY PRECAUTIONS TO BE
OBSERVED
WHEN FUELLING
Engine fuel can cause re or explosion:
• Stop the engine before fuelling and let the machine
cool.
• Do not fuel while smoking or near sparks or ames.
• Do not overll the tank. In case, clean up any spilled
fuel immediately before starting the engine.
WHEN PERFORMING MAINTENANCE
• Always switch off the generator before performing
any service.
• It is not advisable that maintenance operations are
performed by unskilled personnel.
• Always use the necessary individual protection
equipment.
• The battery contains sulphuric acid in solution, and
can cause explosion:
• Always disconnect the battery.
• Never short battery’s positive and negative
terminals, as this can cause battery explosion.
• Battery explosion can cause burns and blindness.
• Always wear protection gloves, face masks and
acid resistant cloth.
• In case of contact with acid do the following:
• In case of splash of acid into the eyes: wash
immediately with clean water and seek medical
advice as soon as possible.
• In case of splash of acid on the skin: wash
immediately with clean water and seek medical
advice as soon as possible.
• In case of ingestion of acid: seek medical advice
immediately.
• When checking the engine oil level or changing the
oil:
• Beware: hot oil can cause burns. Always wear
protective gloves.
BEFORE STARTING THE GENERATOR
(FOR STATIONARY USE)
• Connect the power generator to earth using the
proper terminal and a cable of suitable size without
interposing switches or other devices capable of
breaking the electrical connection. Make sure that
no load is connected to the machine.
WHEN MOVING THE GENERATOR
• When transporting the generator to the place of use,
it must be rmly fastened to the vehicle.
• When moving and transporting the generator, do not
tilt excessively.
• Lift the generator using the lifting eye provided on the
top of the unit.
• If it is necessary to lift the generator using a forklift,
the position of forks in such a way as to balance the
generator weight correctly.
• When lifting and moving the generator, do not stay
or walk within the proximity of the lifting and moving
equipment.
• Never leave the generator slung overhead.
WHEN USING THE GENERATOR (FOR
STATIONARY USE)
• Check that the generator is properly connected to
earth.
• Check that your tools’ cables are in perfect
conditions.
• Make sure that switches and controls are correctly
set for starting (see Chapter 07).
• Operate the generator in well-ventilated areas,
making sure that the exhaust is not restricted.
• Keep the generator away from walls or other
obstructions to avoid the hot air or exhaust recycling
that would cause generator overheating.
• Use fume extractors to ensure the correct air
turnover when operating indoors.
• Do not operate near ammable materials.
• Fill fuel tank when engine is stopped. Do not smoke
when fuelling.
• Do not overll the tank and clean up any spilled fuel.

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02. ACCIDENT PREVENTION / SAFETY REGULATIONS
• Check the level of any liquids that may leak into the
bund. Empty the bund if necessary. Do not dump the
liquids onto land but dispose of them according to
the local legislation.
• Check daily that there are no leaks of liquids from the
engine.
Do not disconnect the battery cables
when the power generator is running.
USES NOT ALLOWED
• Do not connect the power generator to the
commercial electrical grid.
• Do not operate near ammable materials or if
explosive gases or vapours are present.
• Do not operate in narrow or poorly ventilated places.
• Do not operate if the electrical protections are not
effective.
• Do not touch the silencer and the engine parts close
to it.
• Do not perform service when the engine is running.
• Do not tamper with electrical components.
• Any service operation on electrical components
must be performed after stopping the engine and by
skilled personnel.
• Stay away from moving parts and do not get close
wearing loose clothing, ties, necklaces, bracelets,
and anything that can be caught by moving parts.
02.2 RISKS FOR THE OPERATOR WHEN
USING THIS UNIT
ELECTRIC SHOCK
Electric shock can injure or kill. This electric energy can
cause severe or fatal shock to the operator or others in
the workplace.
• Always connect the generator to earth.
• Never touch any parts that are electrically live.
• Repair or replace all worn or damaged parts.
• Install and maintain equipment according to
regulations.
• Switch off the generator and disconnect the battery
before performing any service or repairs.
• Read and follow all the instructions in this Manual.
FIRE AND EXPLOSION
• Fire and explosion can be caused by hot slag or
sparks.
• Be sure there is no combustible or ammable
material in the workplace. Any material that cannot
be removed must be protected.
• Ventilate all ammable or explosive vapours from the
workplace.
• Do not cut or weld on containers that may have held
combustibles.
• Provide a re watch when working in an area where
re hazards may exist.
NOISE
Noise can cause permanent hearing loss.
You must protect your ears from loud noise to prevent
loss of hearing.
• To protect your hearing, wear protective ear plugs
and/or earmuffs. Protect others in the workplace.
• Noise levels should be measured to be sure the deci-
bels (sound) do not exceed safe levels.
• For information on how to measure noise, please
refer to Section 01.3 on page 5.
GASES AND FUMES
Combustion gases produced by the machine, if inhaled,
are hazardous to your health. Make sure that these can
dissipate in the atmosphere without obstructions.
02.3 PROTECTIVE CLOTH RECOMMENDED
FOR OPERATORS
It is recommended that operators wear the following
equipment:
• Coveralls
• Medium/heavy duty gloves
• Acid resistant gloves (only for battery maintenance)
• Protective ear plugs and/or earmuffs
N.B: material not supplied.

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02. ACCIDENT PREVENTION / SAFETY REGULATIONS
02.4 MEANING OF SAFETY SIGNS
These signs inform the user about any hazards that can cause severe injury. Read carefully the meanings and precau-
tions indicated in this manual.
If the original stickers attached to the machine get lost, damaged or even partially unreadable, they must be replaced.
Danger Signs Meaning
Danger of Electrical Discharges
Danger the generator can be started remotely, do not stay in the proximity
Danger of burns: hot surfaces
Danger: do not open when the engine is hot
Danger: belt and fan propeller. Turn off the generator before opening covers or rais-
ing the canopy.
Danger: belt. Turn off the generators before opening covers or raising the canopy
Read and understand the Use and Maintenance Manual bfeore operating the gen-
erator. The machine has been designed in such a way as to guarantee the safe and
reliable operation, as long as the instructions are followed; otherwise personal injury
or equipment damage could result.
Danger of electric discharges: read the manual.

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02. ACCIDENT PREVENTION / SAFETY REGULATIONS
Danger Signs Meaning
Danger of burns! Do not touch the exhaust manifold or the engine when the
generator is in operation.
Stay away from the generator.
Exhaust gases contain carbon monoxide, and other components dangerous to your
health.
Never operate the generator in a closed room.
If installed inside, strictly observe the rules in force about ventilation.
Fuels are extremely ammable, and in certain conditions even explosive.
Fuel in a well ventilated area and after stopping the engine.
Do not bring close cigarettes, sparks or ames while fuelling.
Clean any petrol spill immediately.
Fuels are extremely ammable, and in certain conditions even explosive.
Fuel in a well ventilated area and after stopping the engine.
Do not bring close cigarettes, sparks or ames while fuelling.
Clean any diesel oil spill immediately.
Danger of leaks of corrosive liquids.
Danger of crushing the upper limbs.
Prohbition Sign Meaning
Electrical connections to an emergency grid must be carried out by qualied
electricians and in conformity with the rules in force on that matter. Improper
connections can result in current returns from generator to connected lines. Such
current returns can result in electric shocks received by workers of the electric
company or by people coming into contact with electric lines during failure recovery.
Moreover, as soon as the line is recovered, the generator can explode, burn or
cause res in the building electrical system.
Prohibition of cleaning, lubricating, repairing or adjusting moving parts.
Prohibition of extinguishing res with water; use re extinguishers containing proper
extinguishing agents.
Prohibition of using ames or smoking.

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02. ACCIDENT PREVENTION / SAFETY REGULATIONS
Obligation Signs Meaning
Do not go close to the generator with ames.
Obligation of wearing protection goggles when using grinders, power tools etc.,
connected to the generator.
Do not perform service when the generator is in operation.
Wear protective ear plugs and/or earmuffs when close to the generator.
Information Sign Meaning
Indicates the location of a point for lifting the generator unit.
This card warns that the battery that the has no acid. Before starting the generator,
prepare
the battery according to the instructions of Chapter “06”.
Marks the position of the points for lifting the unit using a fork lift.
HGI Generators Branding Label
HGI Web Address Label

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02. ACCIDENT PREVENTION / SAFETY REGULATIONS
02.5 LOCATION OF SAFETY SIGNS PROVIDED ON THE UNIT

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03. ENVIRONMENTAL DIRECTIONS
03.1- Waste material and lubricating oil.......................................................................................page.17
03.2- Disposal of the unit.............................................................................................................page.17

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03. ENVIRONMENTAL DIRECTIONS
03.1 WASTE MATERIAL AND LUBRICATING
OIL
When running, the generator produces no waste
material.
Spare parts replaced during the unit life and the
lubricating oil are counted as waste, and must be
disposed of according to the laws in force in the country
where the generator is located.
03.2 DISPOSAL OF THE UNIT
Procedure
1. Disassemble the unit and classify its components
according to the following rule:
• Reusable components
• Components made of recyclable material
• Components to be disposed of and lubricating oil
(waste)
The parts so disassembled must be disposed of
according to the laws in force in the country where the
power generator is located.
Do not dispose of any type of lubricating
oil, mineral or synthetic, onto land,drains
or sewers. Dispose of batteries as
instructed by local legislation.

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04. THE POWER GENERATOR
04.1- Generator components........................................................................................................page.19
04.2- SKD100-I Control panel description....................................................................................page.21
04.3- SKD100-IR Control panel description..................................................................................page.22

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04. THE POWER GENERATOR
2
3
4
5
6
7
8
1
1
7
7
7
1
04.1 GENERATOR COMPONENTS
1. Intake screen
2. Control panel
3. Lifting eye
4. Exhaust Vent
5. Fuel Filler Cap
6. Canopy handle
7. Fork Lift Pockets
8. Air Vent Screen
4
3
2
1
5
8
8
6
7
7
1
7
7
7
7
7
7
1

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04. THE POWER GENERATOR
1
2
3
4
5
6
7
1. Radiator tank
2. Fuel lter
3. Coolant ller cap
4. Oil ller cap
5. Oil lter
6. Engine oil level dipstick
7. Fuel pre-lter
8. Alternator battery charger
9. Mufer extension
10. Starter motor
11. Air lter
12. Battery
8
9 10
11
4
12