SGS PGH2200 User manual

PGH2200, PGH3000, PGH6500
FOR YOUR SAFETY
PLEASE READ THESE INSTRUCTIONS CAREFULLY
AND RETAIN THEM FOR FUTURE USE.
OWNER’S MANUAL
PETROL GENERATOR

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WARRANTY
This generator is covered by a 24 month warranty from the initial
date of purchase. This is a domestic warranty provided directly by
SGS Engineering. Please keep a receipt of your pucrchase as this
may be required as proof of purchase.
You will invalidate your warranty if the product is found to have
been misused, tampered with, modified, overloaded or used for a
commercial application for which it was not designed. The warranty
will also be rendered invalid if the maintenance prodcedure has not
been followed.
You must contact SGS Engineering prior to returning any product.
This warranty does not effect your statutory rights.
GENERATOR SAFETY
Only use outdoors.
Never use during wet conditions.
Do not smoke whilst handling fuels.
In emergency, switch engine switch to ‘off’.
Always operate on level ground!
If in doubt about anything, contact us on
([phone].
Always consult this manual for effective product
knowledge.
WWW.SGS-ENGINEERING.COM
CALL FOR ASSISTANCE: 01332 576 850

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EXHAUST GAS PRECAUTIONS
• Always ensure that there is adequate ventilation when
using the generator.
• Always position the generator so that the exhaust is pointing
away from people or animals.
• Never use the generator indoors or in an enclosed area. (i.e work-
shop, garage, lockup etc)
EARTHING THE GENERATOR
• In most situations the frame of a portable generator need not be
grounded (connected to earth) and the frame may serve as the
earth.
• An earth connector lug is fitted to the generator, for use if re-
quired to connect to an earth. This connection should only be
undertaken after full consultation with a competent, qualified
electrician.
• Earth spike not provided as not required for general use.
Exhaust fumes can be fatal!
GENERATOR COMPONENTS LOCATION DIAGRAM
230 V
output
12 V
charging
outputs
Handle
(certain
models only)
Fuel
tank
Air filter box
Key start (cer-
tain models
only)
Wheels
(certain
models
only)
Pull start
115 V
output
Oil
filler
cap
Fuel
gauge
WWW.SGS-ENGINEERING.COM
CALL FOR ASSISTANCE: 01332 576 850

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GENERATOR COMPONENTS LOCATION DIAGRAM
Choke
selector
Spark
plug
Carburettor
adjustment
screw
FIXING THE WHEELS (PGH3000, PGH6500)
1. Push the axle through the
wheel.
2. Slot the wheel and axle
on the frame.
3. Insert split pin through
axle hole and spread pin.
DO NOT tip the generator on its side to fit the wheels.
WWW.SGS-ENGINEERING.COM
CALL FOR ASSISTANCE: 01332 576 850

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FILLING THE GENERATOR WITH OIL
1. Remove the oil
reservoir filter cap.
2. Fill with 10W30 oil to the
centre line of the dipstick.
3. Wipe up any oil spillages
with a rag.
4. Re-insert the oil reservoir
filler cap.
Tip: When filling with oil, use a funnel with a hose.
NEVER tip the generator onto its side to fill with oil.
ONLY USE 10w30 GRADE OIL. Other oils will pre-
vent the generator from starting.
FILLING THE GENERATOR WITH PETROL
1. Unscrew fuel filler cap. 2. Fill with unleaded fuel
until at least 3/4 full.
3. Screw fuel filler cap
closed.
4. Fuel level can be indicated
through the fuel tank window.
Tip: ALWAYS use clean, unleaded petrol in the
generator. NEVER use 2-stroke or other fuels.
WWW.SGS-ENGINEERING.COM
CALL FOR ASSISTANCE: 01332 576 850

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STARTING THE GENERATOR - PULL START
1. Disconnect all
equipment cables from the
230 V and 115 V outlets.
2. Turn the circuit breaker
to the ‘off’ position.
3. Turn the fuel tap down-
wards, this means the fuel
supply is ‘on’.
4. Turn the choke to the
‘left’ position.
STARTING THE GENERATOR - PULL START
5. Switch the engine switch
to the ‘on’ position.
6. Pull the pull starter cord
lightly, until it tenses, then
pull briskly.
7. Once generator engine
starts, move choke lever
over to the right.
THE GENERATOR SHOULD REQUIRE ONLY ONE
OR TWO PULLS TO START. Otherise please contact
SGS Engineering on 01332 576 850.
WWW.SGS-ENGINEERING.COM
CALL FOR ASSISTANCE: 01332 576 850

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STARTING THE GENERATOR - ELECTRIC START
1. Disconnect all
equipment cables from the
230 V and 115 V outlets.
2. Turn the circuit breaker
to the ‘off’ position.
3. Turn the fuel tap down-
wards, this means the fuel
supply is ‘on’.
4. Turn the choke to the
‘left’ position.
STARTING THE GENERATOR - ELECTRIC START
7. Turn the engine start key
to ‘start’ position untill
generator engine starts.
8. Once generator engine
starts, move choke lever
over to the right.
WWW.SGS-ENGINEERING.COM
CALL FOR ASSISTANCE: 01332 576 850

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1. Start the engine and allow to run for a few minutes in order for it
to warm up.
NEVER have any appliances/tools etc plugged in when
starting the generator engine.
2. After engine has warmed up, you can then plug in appliances/
tools into the generator outlets. As a general rule, switch on ap-
pliances/tools etc that you think will take the most power demand
first.
3. ALWAYS ENSURE the correct voltage is selected, using the volt-
age selector.
If the appliance/tool has a standard 3 pin plug it must be
used in conjunction with a flylead and plugged into the
blue socket.
If the appliance / tool has a blue socket attached then it is 230 V,
and must be plugged into the BLUE outlet on the generator.
If the appliance / tool has a yellow socket attached then it is 115 V,
and must be plugged into the YELLOW outlet on the generator.
OPERATING THE GENERATOR SHUTTING DOWN THE GENERATOR
1. Switch OFF any
appliances/tools that are
plugged into any outlets on
the generator.
2. Unplug any appliances/
tools that are plugged into
any outlets on the
generator.
3. Switch the generator to
the ‘OFF’ position.
4. Turn the fuel tap so it is
pointing ‘LEFT’ into the off
position.
WWW.SGS-ENGINEERING.COM
CALL FOR ASSISTANCE: 01332 576 850

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Is there a spark
from the spark plug?
Is the fuel tap
in the down position?
Is 10w30
oil being used?
Make sure fuel tap
is pointing
downwards.
Is the oil level
correct?
Is the choke in the
correct position?
Always use 10w30 grade
oil. If other oil has
been used by mistake,
drain and replace.
Check oil dipstick
and top up
if required.
Ensure choke is in the
correct place.
Refer to starting methods.
Contact SGS Engineering:
([phone]
www.sgs-engineering.com
YES
YES
YES
YES
NO
NO
NO
NO
NO
Troubleshooting flowchart for generator:
Generator will not start.
TROUBLESHOOTING STARTING A GENERATOR GENERATOR TROUBLESHOOTING
PROBLEM SOLUTION
Generator will not start. • Check fuel valve tap is in the ‘down’ position.
• Check the oil level is correct.
• Check 10W30 oil is being used.
• Check choke is in the correct position (refer
to starting methods).
• Check there is a spark - Remove your HT
(high tension) lead from the top of your spark
plug. Remove the spark plug and reconnect
the lead, then touch the metal on the spark
plug against the generator frame. Gently
pull the starter cord mechanism, listen for an
audible ‘ticking’ sound and/or small flashes
coming from the very tip of the spark plug.
If there is no audible ‘ticking’ and/or small
flashes, the spark plug may need replacing.
Generator is difficult to
start.
• The air filter is dirty - clean the filter
• The fuel filter is dirty - clean the filter
• If the pull start mechanism is too ‘hard’ when
trying to pull it, it may denote that there is
too much oil. Check the oil level by using
the dipstick and drain excess oil from the oil
sump bolt at the bottom of the generator.
• If the pull start mechanism feels too ‘slack’
(i.e easy to pull), there may be not enough
compression in the generator engine for it to
work properly. Please contact SGS Engineer-
ing.
WWW.SGS-ENGINEERING.COM
CALL FOR ASSISTANCE: 01332 576 850

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GENERATOR TROUBLESHOOTING
PROBLEM SOLUTION
No electrical output. • Check the breaker switch is up.
• The device being powered is faulty.
• Check that the voltage output switch is set to 115
or 230V.
• Check the connecting lead from the appliance/
tool into the generator is physically sound.
Engine making “rev-
ving” sounds
• If your generator is ‘hunting’ (surging), it may
need a carburettor adjustment. Turn the brass
screw on the carburettor clockwise slowly and
listen for the engine sound. If it does not improve
then try turning the screw anticlockwise.
See our help and advice section for videos and guides on
setting up, starting and maintaining your generator.
http://www.sgs-engineering.com/help-advice
MAINTENANCE SCHEDULE
ITEMS REMARKS
PRE-OP-
ERATION
CHECK
(DAILY)
INITIAL 1
MONTH or
10HR
EVERY 3
MONTHS
or 50HR
EVERY 6
MONTHS
or 100HR
EVERY 12
MONTHS or
300HR
Spark plug
Check condition, adjust
gap and clean. Repeat
if necessary.
X
Engine oil
Check oil level. X X
Replace. X
Air filter Clean. Replace if
necessary. X
Fuel filter Clean fuel drain filter.
Replace if necessary. X
Valve
clearance
Check and adjust when
engine is cold. X
Fuel line
Check fuel hose for
crack or damage.
Replace if necessary
X
Exhaust
system
Check for leakage.
Retighten or replace
gasket if necessary.
X
Check muffler screen.
Clean / replace if
necessary.
X
Caraburet-
tor Check choke operation. X
Starting
system Check key start ignition. X
Decarboni-
sation
More frequently if`
necessary X
Fittings/
Fasteners
Check all fittings and
fasteners. Correct if
necessary.
X
WWW.SGS-ENGINEERING.COM
CALL FOR ASSISTANCE: 01332 576 850

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Tip: Parts replacements are only to be carried out
by competent persons. If in any doubt, please
contact SGS Engineering for help.
Spark plug maintenance. • Remove the spark plug cap from the spark
plug.
• Use a spark plug spanner (supplied) to re-
move the spark plug.
• Check for discoloration and use a wire brush
to remove any carbon build up.
• Check the spark plug gap with a feeler
gauge, it should be between 0.6 and 0.7 mm.
Adjust if necessary.
• Check the overall condition of the spark plug
and replace if damaged.
• Reinstall the spark plug and replace the spark
plug cap.
• CAUTION: ALLOW THE ENGINE TO COOL
BEFORE REMOVING THE SPARK PLUG.
Air filter maintenance. • Remove the air filter element.
• Wash it in a solution of warm water and mild
detergent.
• Rinse thoroughly and leave it to dry. Once it
is completely dry immerse the filter in clean
engine oil and squeeze the filter to remove
excess oil.
• Replace the filter into its original position and
replace and secure the cover.
MAINTENANCE INSTRUCTIONS MAINTENANCE INSTRUCTIONS
Engine oil maintenance. • Warm up the engine on level ground.
• Turn the engine off.
• Remove the oil filler sump plug. Open the
drain sump plug and let the oil drain com-
pletely into a pan placed under the engine.
• Refit the drain sump plug and fill the engine
with clean FOUR STROKE oil only. Replace the
filler cap.
Fuel filter maintenance. • Inside of the fuel tank, there is a fuel filter, this
filter will need checking periodically.
• Remove the fuel cap from the fuel tank.
• Lift out the fuel filter.
• Clean the filter with solvent. If the filter is dam-
aged, contact SGS Engineering.
• Replace the filter and fuel cap.
WARNING: DO NOT SMOKE AND/OR HAVE ANY
NAKED FLAMES
DURING THIS PROCESS
WWW.SGS-ENGINEERING.COM
CALL FOR ASSISTANCE: 01332 576 850

MAINTENANCE INSTRUCTIONS
Draining the fuel. • You should drain your generator of fuel before
you put it into storage.
• Fuel goes stagnant if you left to stand for too
long; this may damage your generator and af-
fect how it runs.
• Pull the fuel hose from the casing while leaving
it attached to the fuel tap.
• Set to the tap to the ON position.
• Place the fuel hose into an appropriate con-
tainer or bottle.
• Tilt the generator towards the fuel hose and
allow all the fiel to drain.
Draining the oil. • Place a tray underneith ther oil sump screw.
• Remove the sump screw
• Tilt the generator towards yourself and allow
all the oil to drain.
See our help and advice section for videos and guides on
setting up, starting and maintaining your generator.
http://www.sgs-engineering.com/help-advice
EC Declaration of Conformity
This is an important document and should be retained
MANUFACTURER’S NAME:
TYPE OF EQUIPMENT:
PART NUMBER:
I, the undersigned, hereby declare that the equipment specied above con-
forms to the above European Communities Directive(s) and Standard(s).
PLACE:
DATE: (Signature)
Robert Wyatt
Company Secretary
Derby, UK
29th DEC 2017
SGS Engineering (UK) Ltd
SGS Engineering (UK) Ltd
1 West Side Park
Raynesway
Derby, DE21 7AZ
Petrol Generator
PGH2200/PGH3000/PGH6500
2004/108/EC Electromagnetic Compatibility Directive
2006/42/EC Machinery Directive
2006/95/EC Low Voltage Equipment Directive
2000/14/EC Noise Emissions Directive (amended 2004/26/EC)
97/68/EC Emission of Gaseious Particulates (emended 2004/26/EC)
EN12601:2001, EN60204-1:2006, EN55012:2002+A1:2005,
EN ISO 3744:1995, ISO 8528-10:1998
APPLICATION OF EC COUNCIL DIRECTIVES / STANDARD:
FOR YOUR SAFETY
PLEASE READ THESE INSTRUCTIONS CAREFULLY
AND RETAIN THEM FOR FUTURE USE.

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R1
R2
L1
L2
AVR
carbon brush
V
10A
L/X L/X
L/X
230V
115V
Low oil sensor
Lgnitiun coil
spark plug
Blue
Brown
Gray
Black
PGH2200 WIRING DIAGRAM
Exciting windingDeputy winding
DC winding
WWW.SGS-ENGINEERING.COM
CALL FOR ASSISTANCE: 01332 576 850

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R1
R2
L1
L2
AVR
carbon brush
V
10A
L/X L/X
L/X
230V
115V
Low oil sensor
Lgnitiun coil
spark plug
Blue
Brown
Gray
Black
PGH3000 WIRING DIAGRAM
Exciting windingDeputy winding
DC winding
WWW.SGS-ENGINEERING.COM
CALL FOR ASSISTANCE: 01332 576 850

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R1
R2
L1
L2
AVR
carbon brush
V
10A
ON
OFF
41236
L/X L/X
L/X
230V
115V
Carburetor solenoid valve
Battery
Start Motor
Low oil sensor
Lgnitiun coil
spark plug
Charging winding
Blue
Brown
Gray
Black
Exciting windingDeputy winding
DC winding
PGH6500 WIRING DIAGRAM
7 8
7 8
WWW.SGS-ENGINEERING.COM
CALL FOR ASSISTANCE: 01332 576 850