SGS SDG8000SELR User manual

FOR YOUR SAFETY
PLEASE READ THESE INSTRUCTIONS CAREFULLY
AND RETAIN THEM FOR FUTURE USE.
OWNER’S MANUAL
DIESEL
GENERATOR

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SPECIFICATION
MODEL No SDG8000SELR
MAX OUTPUT 6500W
RATED OUTPUT 6000W
OUTPUT AC 115 / 230V 50Hz
WEIGHT 165kg
WARNING
Read and understand instructions before use.
Always wear eye/face and hand protection.
The installation and major repair work shall be carried
out only by specifically trained personnel. Install the
generator on a flat, level surface. Safe operation requires
sufficient operator knowledge of the functions and posi-
tions of the controls and indicators.
TECHNICAL SPECIFICATION
Model SDG8000SELR
Type Single-phase alternating current
Excitation System Controllable silicon
Voltage Adjustment Automatic Voltage Regulation
Frequency 50Hz
Rated Output 6.0 Kw
Rated Current 52.17 / 26.08
Power Factor 1.0
DC Output 12V-8.3A 100W
Model Engine SD192
Type Air cooled 4 stroke diesel
Displacement 498cc
RPM 3000RPM
Fuel Diesel Light oil
Fuel Tank 30L
Oil Capacity 1.65L
Starting System Electric
Oil Pressure Protection Yes
Dimensions 918 x 537 x 790mm
Net Weight 170kg
Sound Power Level Lwa 97dB(A)
Noise Test Uncertainty 1.5dB(A)
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WARNING
When Charging The Battery
• Battery electrolyte contains sulphuric acid. Be careful of your eyes, skin
and clothing. Flush thoroughly with water and get prompt medical at-
tention in case of contact, especially if your eyes are affected.
• Charge the battery in a fully ventilated place.
• Be sure to confirm battery polarity.
Electrical Safety
• Electrical equipment (including lines and plug connections) should not
be defective.
• The generating set must not be connected to other power sources
such as the power company supply mains. In special cases where stand-
by connection to existing electrical systems is intended, it shall only be
performed by a qualified electrician.
• Protection against electrical shock depends on circuit breakers
matched to the generating set. If the circuit breakers require replace-
ment they must be replaced with a circuit breaker having identical rat-
ings and performance charateristics.
• Due to high mechanical stresses only tough rubber sheathed flexible
cable (in accordance with IEC245-4) or the equivalent should be used.
• When using extension lines or mobile distribution networks the total
length of lines for a cross section of 1.5mm2 should not exceed 60m;
for cross section of 2.5mm2 this should not exceed 100m.
WARNING
Exhaust Precautions
• Never inhale exhaust gasses. They contain carbon monoxide, a color-
less, odorless and extremely dangerous gas which can cause uncon-
sciousness or death.
• Never operate the generator indoors or in a poorly ventilated outdoor
areas such as a tunnel or cave.
• Exercise extreme care when operating the generator near people or
animals.
• Keep the exhaust pipe free of foreign objects.
Refueling Precautions
• Do not refuel indoors or in a poorly ventilated area.
• Be sure to stop the generator prior to refueling.
• Fuel is combustible and easily ignited. Do not refuel while smoking or
near naked flames.
• Do not over fill the fuel tank. If spilt, wipe away carefully before starting
the engine.
• Diesel fuel oil substitutes are not recommended; they may be harmful
to the fuel system components.
• Fuel should be free of water or dust to prevent damage to the fuel
injection pump and nozzle.
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NAME OF PARTS
Fuel tank
Access panel
DC Circuit Breaker
AC Circuit Breaker
AC Output Sockets
ENGINE OIL
The engine may be damaged if operated with insufficient engine oil. It is
also dangerous to supply too much oil to the engine because a sudden in-
crease in engine rpm could be caused by its combustion. Always check the
oil level before starting the engine and refill if necessary.
Use proper oil to preserve your engine.
We recommend SAE 10W30.
Always use oil with the right viscosity for the ambient temperature in which
your engine is being operated. Use the chart when choosing your engine
oil.
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FILLING WITH ENGINE OIL
When checking the oil level make sure your engine is sitting level. If it is
tilted, you may add either too much or too little oil. If you over fill, your
engine will consume too much oil and the oil temperature will become dan-
gerously high; if you do not add enough oil, your engine could seize up.
When checking the oil, simply dip the
dipstick into the oil pan. Do not screw in
the dipstick.
Be sure to check the engine on a level
surface with the engine stopped.
Replacing engine oil
After engine has been run prior to changing the oil will be very hot. Wear
the correct PPE - a minimum of gloves and overalls.
1. DO NOT allow any dust, dirt or any other debris to enter oil or crank-
case.
2. Remove the oil fillercap.
3. Remove the drain plug and drain the old oil while the engine is still-
warm.
4. The plug is located on the bottom of the cylinder block.
5. After draining, re-tighten the drain plug and refill with the recommend-
ed oil API CH-4/CF/SJ/SL diesel engine oil or higher grade.
BATTERY
When you first install the battery, ensure that the battery’s polarity is the
same as the generator’s battery leads:
Black = negative
Red = positive.
1. Using a voltmeter- check the voltage is 12.3V+, if lower, the battery
must be charged.
2. Check that the voltage is correct every month. The battery should be
between 12.5v and 13.6v. When the engine is running it should re-
charge the battery.
3. Make sure battery is free from damage and is not leaking. If battery
shows signs of damage or leaking – DO NOT continue to use. Instead
replace battery immediately.
4. Make sure that all battery acid spills are correctly cleaned up straight
away.
5. The battery should be stored in a charged condition.
6. The battery is a 12 volt 36Ah sealed lead acid battery and requires no
maintenance other than;
• Ensure battery terminals are kept clean, tight and covered to prevent
shortcircuiting.
• If the battery voltage is too low, it will require charging before use.
• Keep the battery in a cool, dry place. It is important to clean the bat-
tery every three months and charge every six months.
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AIR FILTER
Service the Air Cleaner
• Do not wash air filter with detergent.
• Replace the air filter if the engine output decreases or excessive ex-
haust smoke is noticed.
• Never run the generator without the air filter, otherwise rapid engine
wear will result.
1. Remove the access panel to reveal air filter cover.
2. Undo the nut (anticlockwise) and remove the air cleaner cover and take
out the element.
3. Clean the air filter.
4. Reattach the air filter cover and screw on the nut.
RUNNING IN THE ENGINE
The first 20 hours are the break-in period of the engine. For this
reason, it is important to follow the following instructions during
this period.
1. Warm up the engine 5 minutes after the initial starting, before applying
load.
2. Avoid applying loads above 3kw during the first 20 hours of operation.
3. It is important to replace the engine oil on time
4. Replace the engine oil whilst the engine is warm, after 20-hours run-
ning.
5. Ensure that old engine oil is drained out completely.
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STARTING
1. Turn the main AC switch to the ‘OFF’ position.
2. Make sure that the machine has fuel for the task.
3. Make sure the emergency STOP switch is out (turn anti-clockwise).
4. Set the engine speed lever is set to ‘RUN’.
5. Turn the starting key clockwise to the ‘START’ position. Remove your
hand from the key as soon as the engine starts.
6. If the engine does not start after 10 seconds, wait 15 seconds before
trying again. Excessive start attempts will cause the battery to flatten.
7. If it does not start after 3 attempts, or runs intermittently with excessive
smoke check that the fuel system is fully primed.
8. Always leave the key in the ‘ON’ position whilst the engine is running.
9. Run machine for two minutes before applying load
10. Insert the plug into the socket you are about to use.
11. Turn the main AC switch to the ‘ON’ position and turn the electrical
appliance ‘ON’.
Checks before use
1. Any abnormal sound or vibration?
2. Is the engine misfiring or running rough?
3. What about the color of the exhaust gas? (ls it black or too white?). If
you notice any situation mentioned above, please contact SGS.
PRIMING THE GENERATOR
Before starting to prime make sure that there is fuel in tank and that you
can contain any fuel spilt.
1. Release the pipe clip on the diesel fuel line connected to the injector
pump. Make sure you pinch the fuel line and then release slowly until
all air is released and fuel appears.
2. When fuel appears replace pipe onto the injector pump and replace
clip. Clear up any fuel spills before restarting.
3. The above may be necessary when new, or if the machine runs out of
fuel.
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MAINTENANCE SCHEDULE
Item Daily First
month or
20 hours
Every
100
hours
Every
500
hours
Every year
or 1000
hours
Check and refill with diesel Yes
Check and refill with engine oil Yes
Check for oil leakage Yes
Check and tighten fastening
parts
Yes
Check and tighten head bolts Yes
Replace engine oil Yes,
First oil
change
Yes
Replace engine oil filter Yes
Replace air filter Yes
Replace fuel filter Yes
Check Fuel injection pump Yes
Check injector nozzle Yes
Check fuel pipes Yes
Adjust clearance of intake and
exhaust valves
Yes –
First time
Yes
Grind intake/exhaust valves Yes
Replace piston rings Yes
Check battery condition Yes
Check carbon brushes and slip
rings
Yes
TROUBLESHOOTING
Problem Possible fault/cause Remedy
The Diesel engine
will not start
The governer lever is not at
START position
Set lever to START position
Emergency STOP button
activated(depressed)
Re-set emergency STOP but-
ton
Insufficient fuel Refill with fuel
Fuel injection pump does not
deliver fuel or delivers insuffi-
cient fuel
Remove the injector pump and
have it tested
Check the engine oil level The specified oil level should
be to the upper lever
The injector has severe carbon
build-up
Clean the injector
The start motor turns slowly Check battery performance
and all connections
The battery is flat Charge or replace with a new
one
The generator
is not producing
power
Main breaker switch has not
been turned ON
Turn the main breaker to the
ON position
Alternator brushes worn Replace the brushes
The contact in the socket is not
good
Make sure plugs are fully in-
serted into sockets
The rated sped is too HIGH or
too LOW
Adjust engine speed to pro-
duce 52 Hz with no load
AVR is damaged Replace AVR
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PARTS DIAGRAM PARTS LIST
No Description Part No No Description Part No
1 192FA diesel engine 903629 34 Battery 36AH 903657
2 190 Front end cover 903630 35 M6 Butterfly Nut 903658
3 M8X25 Flange Bolt 902285 36 Battery wire (black) 250MM 903659
4 5.0KW Rotor assembly 903631 37 Battery wire (Red) 700MM 903660
5 Big cushion ring 10x28 903632 38 Glass-fiber insulated foam 903661
6 Spring washer 10.2 903633 39 Muffler 903662
7 M10X265 Flange Bolt 903634 40 Sylphon bellows 903663
8 5.0KW Stator assembly 903635 41 Tooth of Flange nut M8 903664
9 190 Back end cover 903636 42 Fuel tank assembly 903665
10 M6X185 Flange Bolt 903637 43 Fuel pipe clasp 11.5 903666
11 M8X12 Flange Bolt 903638 44 Fuel pipe 903667
12 M6X12 Flange Bolt 903639 45 Fuel pipe clasp 7 903668
13 Flange Nut M5 903640 46 Fuel return pipe 903669
14 Spring washer 5.1 903641 47 Oil filter 904806
15 Flat gasket 5.5*10 903642 48 Big cushion ring 6X18 903671
16 M5X20 Flange Bolt 903643 49 Silent canopy assembly 903672
17 M5X16 Flange Bolt 903516 50 Glass Window 903673
18 Back end cover wire board 903644 51 AVR 904801
19 Carbon Brush 904802 52 Control panel assembly 903675
20 M5X12 Flange Bolt 903646 53 M5X8 Bolt 903676
21 Muffler gasket 903647 54 door lock 903677
22 Canopy inner assembly 903648 55 M8 Flange Nut 900520
23 Rubber part 903649 56 Flange BoltM6*45 903678
24 M8X20 Flange Bolt 902265 57 M6 Flange Nut 903679
25 M6X20 Flange Bolt 903447 58 Muffler gasket 903680
26 Genset base 903650 59 OT head 903681
27 M10X45 Bolt 903651 Regulator 904803
28 M10 Nut 901126 Oil Seal 904804
29 Flat cushion ring 10x18 903652 Air Filter 904805
30 Shock pad 903653 Dip Stick 904807
31 Split pins 3x16 903654 Low Oil Sensor 904808
32 Big cushion ring 12x23 903655
33 4inch Rubber Wheels 903656

SGS Engineering (UK) Ltd
West Side Park
Raynesway
Derby, DE21 7AZ
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
08th NOV 2018
SGS Engineering (UK) Ltd
Diesel Generator
SDG8000SELR
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 (amended 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: