STEELE PRODUCTS SP-GD650E User manual

Owner's Manual
5P-fiDS50E
I_ WARNING! To Reduce The Risk Of Injury, User 1
FORSERVICE CALL:Q@@ OOE EQQt
PAHA SERVIC|Q LLAME: 1818LIm_Li_ LW_I, Jl,W _ &

Preface
This manual will instruct you in the proper operation and service of your diesel
generator. Please read this manual prior to using the generatore to ensure safe and
proper operation. At all times, follow the instructions to keep the generator in the
best working condition and to extend its life. Should you have any comments or
problems, please visit your nearest Steele® location or call 1-888-896-6881.
Please pay particular attention to the warning and caution indicators both within this
manual and on the unit itself.
WARNING) A warning label indicates that severe personal injury or even death
may occur if you do not follow the instructions
.--__ cAUTION ) A caution label indicates that either serious personal injury or
equipment damage may result if instructions are not followed.
This diesel generator will perform safely and to specification if operated according to
the following instructions. Failure to do so may result in serious personal injury
and/or equipment damage.

Warning:
1. Preventthe threat of fire
oNever add fuel while the engine is running,
o Wipe off any spilled fuel with a clean cloth before starting,
o Keep all explosive and flammable items safely away from the generator.
o Maintain adequate ventilation with at least three feet of clear space
on all sides of the generator from buildings and other pieces of
equipment.
o NEVER operate this unit in a closed room or garage.
o Only operate the generator on a level surface
o Do not store the generator indoors while the engine is still hot.
2. Prevent Inhalation of Exhaust Fumes
3,
4,
o Carbon Monoxide isan odorless gas that can kill you!
o Do not operate this generator in a confined space where the exhaust
cannot escape. This means:
•Do not use this unit indoors.
• Do not use this unit in a closed garage.
• Do not attempt to vent the exhaust of this unit outdoors while using
the unit indoors.
o Should you experience a headache, ringing in your ears or begin to feel
drowsy, immediately get some fresh air away from the generator.
Prevent being burned
o The muffler and engine body of this generator get very hot when the
engine is operating or shortly thereafter. Do Not Touch these parts or
you may be severely burned.
Prevent Electrical Shocks and Short Circuits
o To avoid electrical shocks or short circuits, do not:
• Touch the unit with wet hands
• Stand in water
• Operate in the rain or place the unit in standing water

oNote: This generator is not waterproof and therefore should not be
placed in rain, snow, standing water or any area where there could be
water spray. Operating a unit in these environments may cause
electrical short circuits that can cause electrical shocks.
o This generator should also be grounded to prevent electrical shocks
from faulty appliances. To ground this unit, simply connect a length of
heavy copper wire between the unit and a ground source.
oDo Not plug in any power cord until after the unit is operating. If
equipment is attached when starting the generator, it may cause the
unit to move resulting in potential injury.
Caution
•Most appliances require more power to start than their rated wattage.
Therefore make certain that you do not overload the generator with too
many appliances.
• Do not exceed the current limit of any of the electrical outlets on the generator.
• Do not connect the generator to a household circuit. This may cause
damage to the generator and also to the wiring in your house, as well as
the electrical appliances.
5. Batteries:
• Batteries contain sulfuric acid which can burn your eyes and skin.
Whenever working with a battery, protect your eyes and skin from
exposure to the acid. In case of contact with any acid, act immediately by
thoroughly flushing the affected area with clean cold water and seek
prompt medical attention.
• Batteries also generate hydrogen gas which can be extremely explosive.
Do not smoke or allow flames near a battery, especially while in a
charging mode. Always charge batteries in a fully ventilated area.

ADANGER
CARBON MONOXIDE
Using a generator indoors WILL KILL YOU IN MINUTES.
Generator exhaust contains high levels of carbon monoxide (CO), a
poisonous gas you cannot see or smell• tf you can smell the generator
exhaust, you are breathing CO. But even If you cannot smell the exhaust,
you could be breathing CO.
• NEVER use a generator inside homes, garages, crawtspaces, or other
partly enclosed areas. Deadly levels of carbon monoxide can build up in
these areas. Using a fan or opening windows and doors does NOT supply
enough fresh air.
•ONLY use a generator outdoors and far away from open windows, doors,
and vents. These openings can pull in generator exhaust•
Even when you use a generator correctly, CO may leak into the home.
AUv'VAYSuse a battery-powered or batten/-backup CO alarm in the home.
tf you start to feel sick_ dizzy, or weak after the generator has been running,
move to fresh air RIGHT AVVAktSee a doctor• You could have carbon
monoxide poisoning

1.TechnicalSpecificationsandData.............................................1
2.Configurations 2
3.BeforeStartingYourGenerator.............................................4
4.Sta_ingtheGenerator.........................................................8
5.OperatingYourGenerator........................................................9
6.YourGenerato_Capacity.........................................................10
7.StoppingYourGenerator.....................................................14
8.PeriodicMaintenanceandTesting........................................15
9.Long-TermStorage....................................................................19
10 Troubleshooting& Solutions................................................20
11, Parts Diagram .................................................................................21
12. LimitedV'_nty .................................................................................32

1.Techcial Specifications and Data
Model SP-GD650E
Rated frequency 60 Hz
Rated voltage 240V /120V
Rated current 21A /42A
Rated output power 5,000 watts
Max output power 6,500 watts
Rated rotation speed 3,600 RPM
Phase number Single
Pole number 1
Excitation transistorized Self-excitation constant voltage (AVR)
Panel type T: General panel TA: Digital control panel
Structure type Silent type
Fuel tank capacity 4 Gal
Fuel consumption 360 g/kw.h
Continuous running time 9 1/2 hours at 1/2 load
Starter system Electric starter
Fuel type Diesel
Engine model TD186
Engine type Single cylinder, 4-stroke, air-cooled, vertical,
diesel engine
Borexstroke 86 mm x 72 mm
Displacement 0.418cm 3
Compression ratio 19:1
Rotation direction (from the flywheel) clockwise
The lowest fuel consumption(g/kw.h) 3,600 RPM:281

2. Configurations
2.1 Parts name
AC output Circuit breaker(AC SW)
DC output
Engine starter swffch
Low oii pressure
Fue! filler _p indicator _amp
Outlet for
c_ling air

2_2 Control panel
3

3. Before Starting Your Generator
3.1 Selection and handling of diesel fuel
•Only use light diesel fuel
• Keep dust and water out of the fuel. Failure to do so will create problems
with the injection pump and nozzles.
•Do not overfill the tank beyond the red plug inside the fuel oil filter. Doing
so can be very dangerous.
Warning:
• Refuel in a well-ventilated area with the engine off.
• Do not smoke or allow open flames or sparks near where you are
refueling or where the fuel is stored.
• Do not overfill the tank. Make sure that the fuel cap is securely tightened
after refueling.
• Do not spill any fuel. If fuel is spilled, make certain that the spilled fuel is
removed before starting the engine.
3.2 Check and refill engine oil
Warning:
• Before every start, make sure that your generator is on a leveled surface
and then check the oil level.
• The engine may be damaged if it is operated with insufficient oil.
• Too much oil may cause a sudden increase in engine speed also
damaging your generator.
Caution: Your diesel generator is equipped with a "low oil" warning system. This
system automatically stops the engine when the oil level becomes dangerously
low, preventing major damage to your generator. Do not rely totally on this
system for maintaining proper oil levels, as it only represents an emergency
situation and not a method for checking your generator's oil level.

• Oil Selection
it is very important that you seiect the prope_ engine oi_ to maintain the life and
performance of your generator, if inferior or the wrong weight oil is used, or if your
engine oil is not replaced periodically, there is a risk of major damage to your
engine due to overheating.
Choose the applicable viscosity according to your local temperature.
When adding oil for the first time add no more than one to one and a haft quarts
of oil If the iow oit tight comes on, add about another quaR of oil to the unff,
3,3 Sewicing the air filter
1 Remove the wing nut from the air
filter _p and then the cover itself,
This wilt allow you to remove the filter.
Caution:
• Do not wash the filter with
detergent,
Replace the air fi_ter when it
impedes the flow of air and cannot
be completely cleaned. One
indicator is when the engine
exhaust changes color.
•Never operate the generator
without the air filter,

2, Reattachtheairfi_tercoverand
tighten the wing nut.
Ei_.tmet_t
3.4 Checking the Gene_tor
1. Make sure that you turn off the
main switch and any other e{ectrical
load before inspecting the generator.
Warning:
• Turn off the main switch
before starting
• The generator must _ grounded to prevent etectric shock
2, O_rating dual voltage generators,
• Make sure that you use the correct outlet for the rated voltage
device being powered, dthe
Caution:
•The main switch must be in the "on_ position during operation.
Before sta_ing the engine unplug the devices to be powered or
make sure that aii dthe devices are turned "off", If the switches for the
devices are le# in the "on" position and the generator is started the sudden
surge in power can be very dangerous.

3_5 How to open the cabinet door and
coven on the gene_tor.
t Always open the generator cabinet door
and inspect the engine prior to sta_ing
the generator. To do this, simply turn the
lever counterclockwise and raise the
door
2_ Loosen the wing nu_ on the air cleaner
and inspect the cieaner.
3. Open the wing nut on the cover and
inspect the nozzle cover,
remove the protective
3,6 Breaking in your new generator
The first 20 hours of operation are required to property seat your generator's
operating parts_ During this period, the fo}Iowing steps _ be taken:
•, During the {nffiai operation, run the generator at a_ow speed with nothing
p;ugged in for aminimum of five m_nutes.
• Avoid app]ying any heavy demands to the unit during the break-in period,
Matrix recommends that the engine be operated at 3_000 RPM w_h no more
than a 50% ioad for the first 20 hours of operation.
•Change the lube oi_ a_er 20 hours of initia_ operation or at the end of the first
month,then eve_ three months or 100 hours thereafter
%>
-L"

4. StaGing the Generator
Warning: De net plug in anyteeis er devils prierte starting yeur g_nerater.
4.1 E_ectric S_rt_ng
I Starting ( The preparatiens for e_ectric
starting are the same as receiI
starting)
. O_n the fuel valve
,, Turn the ignition key cleckwise to the "START" pesitien and remove your
hand ffem the key as seen as the engine starts, If the engine dees net
start in 10 secends just wait 15 secends and re.at the precess.
Engine starter key
8

2. Battery: if the battery has an open ceii
design, check the water leve! every month_
If it is _ow, refill using distilled water until
the cell is full. If the battery is a sealed unit,
check for cracks and Beaks
Caution
if the distilled water level is too Iow the engine may fail to start because there
isn't sufficient batter.,/ power, if the water ievet is too high, the fluid will corrode
surrounding parts shortening the _ifeof the battery. Always maintain the ievei of
distilled water at the recommended level Never use well or tap water as the
minerals in the water will destroy your battery.
5. Operating Your Generator
Before plugging anything into the
generator, let your generater run
for a minimum of three minutes at
normal speed.
2. If your generator has a "low oil"
_ight, check to make certain that it
is not i_luminated,
Caution
• The low oil warning iight is activated by either a low pressure level or an
inadequate amount of oil in the reservoir.When the low oil iight is activated,
9

the engine will automatically stop. If you attempt to start the generator
without addressing the problem, the unit will not start. When the "low oil"
light illuminates, check the oil level first to make certain that there is
adequate oil in the reservoir.
Do not adjust either the engine governor bolt that controls engine speed or
the fuel injection bolt that controls fuel mix. Doing so will affect the overall
performance of your generator.
5.2 Operational System Checks
•Determine whether there is abnormal sound or vibration
• Determine whether the engine misfires or runs rough.
• Examine the color of the exhaust. If it is too black or too white, shut off your
generator.
Caution:
• If your generator has been in operation, the muffler will be extremely hot. Do
Not touch the muffler as you can be severely burned.
• Never refill the fuel tank while the engine is running.
6. Your Generators Capacity
Caution
• Do not attempt to start two or more devices simultaneously. First plug in or
start one device, then the next, and then the next.
6.1 AC application
• Make certain that you operate the generator at its rated speed in RPM's. If
this is not done, the AVR or Automatic Voltage Regulator will incorrectly
produce too much voltage shortening the life of the AVR.
• After switching on the circuit breaker, check the voltmeter on the control panel.
The voltmeter should point to 120V +/- 5% for a single phase generator and
230V +/- 5% (50 Hz) for a multiphase generator.
10

• Whenthedualvoltagegeneratorexceedsorisbelowtheselevels,thenthe
circuitbreakershouldbeinthe"OFF"position.Ifnotboththegeneratorandthe
devicespoweredbyitcanbedamaged.
• Alwaysconnectdevicestothegeneratorwiththehighestdemanddevice
firstandthenthelesserdemanddevicesafterward.If theoperation
becomesoverloaded,thegeneratorenginewilllagorstopsuddenly.Ifthis
happens,unplugalldevicesimmediately,turnoffthemainswitchonthe
generatorandcheckallsystems.
• Threephasegenerators
• Makecertainthatyoubalanceallthreephasesduringoperation.Stop
theengineandchecktoseeifthegeneratingisoperatingwithin20%of
specification.Iftheengineisnot,reduceyourloadorturnoffthe
generator.
• Thesumoftheloadforeachphasemustbebelowtheoverallrated
load.Inaddition,theoverallcurrentdrawnmustbelessthantheoverall
ratedcurrent.
• ThephasearrangementA,B,C,D(orU,V,W,N)shouldbefromleft-
to-rightorclockwise.
• Ifyouareattemptingtostartthreenon-synchronousmotors,always
startwiththeheaviestdutymotorfirstandthenprogresstothelighter
dutyunits.
Note:Ifoverloadingthecircuittripsthecircuitbreaker,reducetheelectricalload
onthecircuitandthenwaitafewminutesbeforeresumingoperation.
6.2 DC application
1. The DC terminals are only for charging the 12V battery included with your
generator.
2. Set the circuit breaker in the "OFF" position while charging the battery. On the
12V output terminals, a charge switch can be installed so that the unit can
be turned on and off as desired.
3. If your generator has an automatic battery with separate leads, make certain
that you disconnect the negative lead while you are charging the battery.
11

Cauti on
• Identify and connect positive-to-positive and negative-to-negative poles from,
the battery to the engine, Crossing the wires will destroy both the battery
and the electrical components of your generator,
• If you attempt to use a larger battery than recommended you will create
excessive current that will blow the fuse in the generator,
• Do not attempt to operate the generator while it is still connected to the
battery,
• Do not use a 12V DC and AC current at the same time,
Caution
• All lead batteries emit explosive gas when being charged. Keep sparks,
flames and cigarettes away from the battery while charging. To prevent
sparks, always connect the booster cables to the battery first and then to the
generator. When the battery is charged, disconnect the cables from the
generator first.
• Charge the battery in a well ventilated place.
• Unless the battery is sealed, remove the caps from each cell before
charging.
Stop charging if the battery feels extremely hot. If the temperature exceeds
45C or 113F then the battery is too hot.
12

6.3 All electrical appliances, particularly motor driven equipment,
have extremely highly levels of current draw during their start_up
period. The table below provides a quick reference regarding
connecting different types of devices to the generator.
TYPE
_ncandeo
scent
lamp
, Heating
appliam
ce
WA_AGE
STARTINGIRATED
x1 x1
TYPICAL
APPLIANCE
In_ndes_nt
_amp TV
EYJ&,MPLE
APPLIANCE
incandescent
lamp
lOOW
. Fluoresc-
ent X2 X_.5
_amp Fluorescent
lamp
• Motor-
driven X3~5 X2
equip-
meat
Refrigerator
Electric
fan
Refrigerator
150W
RATED
100VA IOOVA
(w) (w)
80VA 6OVA
(W) (W)
300VA
13

7. Stopping Your Generator
Step I: Disconnect aHelectrica{ plugs from the generator outiets _fore turning
off the generator!
Step i1: Turn off the circuit breaker on the generator.
Step Ill:: Set the starter lewel in the "run" position, operating the generator for
about three minutes with nothing plugged in. Note: Do Not stop the generator
without this step as the operating temperature of the engine wih'increase thereby
damaging the unit.
Step IV: Depress the "step" _ever
Step V: if the unff has an recoil starter turn the key to the "off" position.
1. Move the fuel lever to the "Stop" position,
Step V[:: Retract the recoi[ sta_er handie until you feei resistance. (At this point
both the intake and exhaust valves are closed), Leave the handJe in the position
as it prevents damp air from entering the engine and thereby prevents rust from
forming.
Warning:
• Should the engine continue to operate when the starter lever is placed in
the "Stop ° position, either turn the fueI valve to the °Close ° position or
toosen the nut of the high pressure fuel pipe on the pump side of the
engine, ff you do this, remember to tighten it again before attempting to
sta_ the engine.
= Do not attempt to stop the engine with the decompression iever.
= Always make certain that aiI electrica_ piugs are removed from the
generator outlets before turning off your generator,
14