Stephill SE6000D4 User manual

Issue 6 15/06/2015
SE6000D4 - SSD6000 - SSD6000S NSM
Handbook
Stephill Generators Ltd
Wallis close
Park Farm South
Wellingborough
Northants
NN8 6AG
Tel : [phone]
Fax : [phone]
E-mail : [email protected]o.uk
Web : www.stephill-generators.co.uk
DO NOT OPERATE THE GENERATOR BEFORE READING THIS MANUAL AND ENGINE
MANUFACTURER’S OWNER’S MANUAL AND WARNINGS.
THIS STEPHILL GENERATOR HAS BEEN DESIGNED TO PROVIDE SAFE AND EFFICIENT SERVICE
IF OPERATED AND MAINTAINED CORRECTLY.
MANY ACCIDENTS OCCUR THROUGH FAILURE TO ADHERE TO FUNDAMENTAL SAFETY
PROCEDURES.

Issue 6 15/06/2015
Contents
Page
1
SPECIFICATION
1
2
GENERAL SAFETY
1
2.1
Warning signs
1
2.2
Safety hazards
1
3
POTENTIAL HAZARDS
1
3.1
Auxiliary power
1-2
3.2
Operating environment
2
3.3
Temperature range
2
3.4
Reference relative humidity
2
3.5
Reference barometric pressure
2
3.6
Flammable environment
2
3.7
Saline environment
2
4
SAFETY CONSIDERATIONS
2
4.1
General
2
4.2
Fuel
2
4.3
Lubricating oil
2
4.4
Safe lifting
2
4.5
Earth connection
3
4.6
Fumes
3
4.7
Noise
3
4.8
Battery acid
3
4.9
Fire
3
4.10
Hot parts
3
5
OPERATING INSTRUCTIONS
3
5.1
Pre-Start checks
3
5.2
Warning
3
5.3
Fuel system bleeding procedure SE6000D4
3-4
5.4
Fuel system bleeding procedure SSD6000/S
4
5.5
Control panel
4
5.6
Long term storage
4
6.0
KEY START OPERATING INSTRUCTIONS
5
6.1
Fault finding key start
5
7.0
DEEP SEA 3110 OPERATING INSTRUCTIONS
6
7.1
Description of controls
6
7.2
Starting the engine
6
7.3
Starting sequence
6
7.4
Engine running
6
7.5
Stopping the engine
6
7.6
Automatic operation
6
7.7
Waiting in auto mode
6
7.8
Viewing the instruments
7
7.9
Fault icons
7-8
7.10
Fault finding 3110
8-9
8
SERVICE AND MAINTENANCE
10
8.1
Engine service
10
8.2
Alternator service
10
9
Alternator spares
10
10
Yanmar consumable spares
10
11
General spares
10-11
12
SE6000D4 Spares
11
13
SSD6000 Spares
12
14
SSD6000S Spares
12
15
WARRANTY
12
L100 Key switch wiring diagram
13
L100 Deep sea 3110 wiring diagram
14
Dual voltage AC wiring diagram
15
SE6000D4 Base exploded view
16
SE6000D4 Roof exploded view
17
SSD6000/S Base exploded view
18
SSD6000/S Roof exploded view 19

Issue 6 1 15/06/2015
1 Specification
SE6000D4
SSD6000
SSD6000S
kVA
6.0
6.0
6.0
kW
4.8
4.8
4.8
LWA
96
91
84
dBA@7M
71
66
59
Engine
Yanmar L100
Yanmar L100
Yanmar L100
Alternator
NSM M100 SG
NSM M100 SG
NSM M100 SG
Voltage
230v &115v CTE
230v &115v CTE
230v &115v CTE
Weight
174Kg
196Kg
230Kg
Length
1220mm
1290mm
1290mm
Width
710mm
785mm
785mm
Height
910mm
890mm
970mm
Fuel
24L
24L
24L
Hours run 100% load
13
13
13
Hours run 75% load
17
17
17
2 General Safety
2.1 Warning signs
Warnings shown on the machine should be observed at all times. The warning signs
should be checked for legibility and any that have become damaged should be replaced.
The following are shown on the generator:
2.2 Safety hazards
Do not climb on the generator, as dents may cause overheating of the acoustic lining. It is
important to keep the generator clean and well serviced, in particular keep all air vents /
louvers clear of debris to prevent poor performance or possible overheating and
permanent damage to the generator.
Keep well clear of moving parts on the generator at all times.
Children and pets must be kept clear of the operating area.
3 Potential Hazards
3.1 Auxiliary power
The electricity produced by an engine driven Generator is very similar to mains electricity
and should be treated accordingly.
Do not remove covers and attempt to work on the Generator while the engine is running.
Check the rating and electrical safety of the load before connecting the Generator.
CAUTION
HOT EXHAUST
RISK OF ELECTRIC SHOCK
ALWAYS TURN OFF GENERATOR
BEFORE OPENING. KEEP
CLOSED AT ALL OTHER TIMES
BEFORE STARTING.
READ HANDBOOK AND SAFETY ADVICE
CHECK OIL LEVEL
DO NOT ADJUST ENGINE SPEED
WITHOUT SUITABLE TEST EQUIPMENT
WARNING

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Equipment should never be connected that in total exceeds the specified rating of the
Generator.
Installation of the generator as a standby or secondary power source should only be
undertaken by a fully qualified electrician using the appropriate means of isolation from
the mains supply. Installation must comply with all applicable laws and electrical codes.
3.2 Operating Environment
The Generator should always be operated on level ground.
3.3 Temperature Range
A temperature range between -10˚C and +40˚C are the normal limits of operation.
Operating outside the range will require additional modifications.
3.4 Reference Relative Humidity
The standard reference condition for relative humidity is 30%. Above this value the rated
power must be reduced.
3.5 Reference Barometric Pressure
The standard reference condition for total barometric pressure is 1 bar.
This corresponds to an altitude of approximately 100m. Above 100m the rated power
must be reduced.
3.6 Flammable Environment
Stephill Generators must not be used in a flammable environment.
3.7 Saline Environment
Operation of the machine in a saline environment will require additional corrosion
protection.
4 Safety Considerations
4.1 General
All Stephill Generators comply with all the current EEC directives including:
2006/42/EC Machinery Directive
2000/14/EC Noise Emission in the Environment by Equipment for use Outdoors
2004/108/EC EMC Directive
2006/95/EC Low Voltage Directive
4.2 Fuel
Fuels and lubricants are a potential source of fire. Lubricants in particular used engine oil,
are potentially carcinogenic. Direct contact should always be avoided by wearing suitable
rubber gloves when handling them. Be careful not to spill fuel, clean up any spillages.
Inhalation or swallowing of Diesel should be avoided. If in doubt seek medical advice. All
other forms of contact are irritant and therefore should also be avoided. If skin contact is
made wash with soap and water.
4.3 Lubricating Oil
New oil presents no hazard following short term exposure.
Used oil should not be allowed to contact the skin. If this does occur, wash off quickly
with a proprietary hand cleanser.
4.4 Safe Lifting
Where mechanical assistance is used in lifting machines, ensure the lifting eye is used,
and that all components used to lift the machine are within their Safe Working Load
(SWL).
The integral lifting beam and associated lifting eye on the generator should be regularly
checked for signs of damage or gross corrosion.
All Nuts and Bolts associated with the lifting beam should be regularly checked for
tightness and corrosion.
Lifting equipment should not be attached directly to the Engine/Alternator except for lifting
of Engine/Alternator only.

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4.5 Earth connection
All Stephill products are fitted with an earth stud on the control panel this must be
connected to an earthing system or spike. Any earth spike required is dependant on the
local conditions of use. The size is determined by reference to current IEE regulations or
to a competent electrician.
4.6 Fumes
Make sure that the Generator is at least 2 metres away from any building during
operation. Operate in a well ventilated unconfined area, so that fumes can be properly
dispersed.
Silencer outlet should be facing an open area to prevent fumes being recirculated. There
is the danger of asphyxiation due to exhaust gases. Inhalation of poisonous exhaust
fumes can lead to serious injury or death. The generator must not be used in a poorly
ventilated or enclosed area.
4.7 Noise
Ear protection may be required depending on the combined noise level of the Generator,
auxiliary load and the operator’s distance from it and the length of exposure. (Noise at
Work Regulations 1989)
4.8 Battery Acid
This is corrosive and irritant by all forms of exposure. Direct contact should always be
avoided by wearing suitable rubber gloves, some form of eye protection should also be
used. If skin contact is made wash with clean water.
4.9 Fire
Ensure that suitable fire extinguishers (AFFF or CO2)are kept within proximity to the
generator. Do not cover, enclose, or obstruct the airflow to the generator during or shortly
after use, due to fire hazard or damage to the generator from overheating. Allow the
generator to cool after use before storing away. Keep all inflammable objects clear of the
Generator.
4.10 Hot parts
There is the danger of burns as parts of the generator will become very hot during use.
No part of the engine, alternator or exhaust must be touched during or shortly after
operation. Do not operate the generator unless all guards are in place. There is a risk of
burns or serious personal injury.
5 Operating instructions
5.1 Pre-start checks
Before starting the generator please read the Yanmar engine owners manual.
Check Fuel & Oil level before attempting to start.
The generator is equipped with a low fuel level switch which will shutdown the engine and
prevent it from starting, if the fuel level is low.
The engine is equipped with an oil and temperature switch and will shutdown for low oil
pressure and high engine temperature.
5.2 Warning
Do not operate the changeover switch with load connected.
Always switch load off before disconnecting plugs.
To switch power off at the Generator always use the circuit breaker.
5.3 Fuel system bleeding procedure SE6000D4
Before attempting to bleed the fuel system on the SE6000D4, ensure the key switch is in
the off position, the tank has a minimum of 10 litres of fuel and the lid is open.
1. Loosen the Brass injector pipe fitting (17mm nut) on the fuel pump, move to one side,
leaving the delivery valve holder (black male fitting) on the fuel pump exposed.
2. Loosen the Delivery valve holder (17mm nut) but only by 2 complete turns.
3. Turn the starter key to the on position, (do not start the generator). The battery and
low oil pressure warning lamps should be illuminated.
4. Then slowly turn the starter key to the spring position until the battery warning lamp
goes out. You should also hear the fuel solenoid click to indicate it is open. Hold the

Issue 6 4 15/06/2015
key in this position until all the air has escaped from the delivery valve holder fitting on
the fuel pump and diesel starts to trickle out, then turn the starter key back to the off
position.
5. Then tighten the Delivery valve holder and the Brass injector pipe.
Now the fuel system has been bled and the generator should start.
6. If the engine still will not start repeat steps 1-5 but turn key to start position and diesel
should squirt out of delivery valve holder. Once this has been achieved go to step 6.
Injector pipe fitting Delivery valve holder
5.4 Fuel system bleeding procedure SSD6000/S
A self-bleeding system is fitted to these generators; the engine should not need
bleeding unless maintenance has been carried out.
Before attempting to bleed the fuel system on the SSD6000/S ensure the tank has at
least 10 litres of fuel.
1. Turn the starter key to the first position, do not start the generator. The battery and
low oil pressure warning lamps should be illuminated.
2. Then slowly turn the starter key to the spring position until the battery warning lamp
goes out. You should also hear the fuel solenoid click to indicate it is open; the fuel lift
pump will also be operational. Hold the key in this position for around 1 minute, turn
the starter key back to the off position.
Now the fuel system has been bled and the generator should start.
Note: If a Deepsea 3110 control module is fitted to the generator you have a fuel
pump prime button to bleed the system with.
5.5 Control panel
Before connecting plugs into generator ensure the load is turned off. If this is not possible
turn the circuit breaker to the off position.
The 230v Supply is Neutral bonded to earth.
The 115v Supply is CTE. (Centre Tapped to Earth)
Turn the voltage selector switch to the required voltage.
Connect the plug/plugs into the generator.
Switch on the load / Circuit breaker.
Always turn load off before stopping generator.
5.6 Long term storage
For storage or long periods of inactivity, Stephill Generators recommend the following:
Generators should be stored with oil filled to the correct capacity; Storage periods of 18
months and over may require special lubricants and treatments. If so please seek further
advice from the engine manufacturer.
Before the generator is used after long term storage, all fuels and oils should be replaced.
Generator mounts, pipes and hoses should be checked to ensure that they are un-
perished following extended periods of storage.
The generator should be stored in a clean dry area, ideally having a reasonable constant
ambient temperature, and ideally not below freezing.

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6 KEY START OPERATING INSTRUCTIONS
Before attempting to start the generator ensure the engine has the appropriate amount of
lubricating oil and the fuel tank has at least 10 litres of diesel.
Turn the key to the first position, the oil and battery lamps should be illuminated.
Turn the key to crank position until engine fires, oil and battery lamps should now have
been extinguished.
Return key to run position and the generator should now be running.
To stop, turn the key to stop position.
6.1 Fault finding key start
Before diagnosing a possible fault ensure all the bulbs in the fault lamps are working.
The easiest way to check is to swap the lamp heads containing the bulb into a holder
you know works eg. the battery or oil lamp. A blown bulb will not show you a possible
fault!
Fault
Possible cause
Check
Starter motor not
engaging & not
starting
Battery
Reset button
Faulty wiring
Faulty starter motor
Check battery voltage, should be about 12.5V.
Check electrolyte level in battery.
Check DC reset button on control panel.
Check for loose wires on starter motor.
Check continuity from key switch to reset
button.
Check continuity from key switch to starter
motor.
Check / Change starter motor.
Starter motor
engaging & not
starting
Faulty lamps/lamp holder
Run-Stop lever in wrong
position
Fuel lamp illuminated
Full of fuel still won't run
Temperature lamp lit
Fuel Solenoid
Check bulbs and lamp holders.
Move to Run position.
See fuel lamp fault.
Check machine has not run out of fuel and
introduced air into system (bleed).
See temperature lamp fault.
Check 12v supply to solenoid.
Check solenoid is operating.
Check connections on key switch.
Battery charge
lamp illuminated
when running
Fuse blown
Wiring
Regulator
Fuse holder situated next to regulator
Check regulator and harness connections.
Check continuity (earth connection) from
regulator to body of engine.
Check AC voltage on green/white wires from
engine voltage should be 38V.
Check key switch connections.
Replace regulator.
Oil lamp stays
illuminated
during start
procedure
Low oil
Oil pressure switch
Oil pressure relay
Check oil level is at max on dip stick.
Check for signs of oil leak.
Check oil pressure switch normally closed
when engine is at rest and open when engine
running.
Replace Oil pressure switch.
Check relay for loose wires.
Check operation of relay.
Temperature
lamp stays
illuminated during
start procedure
Temperature switch
Temperature switch relay
Check operation of temperature switch
normally closed opens with fault.
Check relay for loose wires.
Check operation of relay.
Fuel lamp stays
illuminated during
start procedure
Low fuel
Faulty level switch
Fuel level relay
Check fuel level is at 1/3 a tank minimum.
Check level switch operation normally closed
with low fuel, opens when fuel level ok.
Check connections on level switch.
Check relay for loose wires.
Check operation of relay.

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7 DEEP SEA 3110 OPERATING INSTRUCTIONS
7.1 Description of controls
7.2 Starting the engine
To begin the starting sequence, press the button.
The icon is displayed to indicate Manual mode and the manual LED flashes.
The button must be pressed once more to begin the start sequence.
7.3 Starting sequence
If a start request is present, the fuel relay is energised and the engine will be cranked. If
the engine fails to fire during this cranking attempt then the starter motor is disengaged
for the crank rest duration after which the next start attempt is made. Should this
sequence continue beyond 3 attempts, the start sequence will be terminated and the
display shows Fail to Start.
When the engine fires, the starter motor is disengaged. Speed detection is factory
configured to be derived from the main alternator output frequency.
After the starter motor has disengaged, the Safety On timer activates (10 Sec), allowing
Oil Pressure, High Engine Temperature, Under-speed, Charge Fail and any delayed
Auxiliary fault inputs to stabilise without triggering the fault.
7.4 Engine running
Once the engine is running and all starting timers have expired, the animated icon is
displayed.
If all start requests are removed, the stopping sequence will begin.
7.5 Stopping the engine
In manual mode the set will continue to run until either:
The stop button is pressed –The set will immediately stop
The auto button is pressed. The set will observe all auto mode start requests and
stopping timers before beginning the Auto mode stopping sequence.
7.6 Automatic operation
Activate auto mode by pressing the pushbutton. The icon is displayed to
indicate Auto Mode operation if no alarms are present.
Auto mode will allow the generator to operate fully automatically, starting and stopping as
required with no user intervention.
7.7 Waiting in auto mode
If a starting request is made, the starting sequence will begin.
Starting requests can be from the following sources:
Activation of an auxiliary input that has been configured to remote start.

Issue 6 7 15/06/2015
7.8 Viewing the instruments
It is possible to scroll to display the different pages of information by repeatedly operating
the scroll button
Once selected the page will remain on the LCD display until the user selects a different
page or after an extended period of inactivity, the module will revert to the status display.
When scrolling manually, the display will automatically return to the Status page if no
buttons are pressed for the duration of the configurable LCD Page Timer.
If an alarm becomes active while viewing the status page, the display shows the Alarms
page to draw the operator’s attention to the alarm condition.
Page order:-
Engine speed
Generator volts
Generator frequency
Engine run time
Battery volts
7.9 Fault icons
AUXILIARY INPUTS
Auxiliary inputs can be user configured and will display the message
as written by the user.
FAIL TO START
The engine has not fired after the pre-set number of start attempts.
FAIL TO STOP
The module has detected a condition that indicates that the engine is
running when it has been instructed to stop.
LOW OIL PRESSURE
The module detects that the engine oil pressure has fallen below the
low oil pressure pre-alarm setting level after the Safety On timer has
expired.
ENGINE HIGH
TEMPERATURE
The module detects that the engine temperature has exceeded the
high engine temperature pre-alarm setting level after the Safety On
timer has expired.
UNDERSPEED
The engine speed has fallen below the underspeed pre alarm
setting.
OVERSPEED
The engine speed has risen above the overspeed pre alarm setting.
CHARGE FAILURE
The auxiliary charge alternator voltage is low as measured from the
W/L terminal.
LOW FUEL LEVEL
The level detected by the fuel level sensor is below the low fuel level
setting. (Optional)
BATTERY UNDER
VOLTAGE /
BATTERY
OVER VOLTAGE
The DC supply has fallen below or risen above the low/high volts
setting level.
GENERATOR UNDER
VOLTAGE
The generator output voltage has fallen below the pre-set pre-alarm
setting after the Safety On timer has expired.
GENERATOR OVER
VOLTAGE
The generator output voltage has risen above the pre-set pre-alarm
setting.
GENERATOR UNDER
FREQUENCY
The generator output frequency has fallen below the pre-set pre-
alarm setting after the Safety On timer has expired.
GENERATOR OVER
FREQUENCY
The generator output frequency has risen above the pre-set pre-
alarm setting.
EMERGENCY STOP
The emergency stop button has been depressed. This is a failsafe
(normally closed to battery positive) input and will immediately stop
the set should the signal be removed. Removal of the battery positive
supply from the emergency stop input will also remove DC supply

Issue 6 8 15/06/2015
from the Fuel and Start outputs of the controller.
INTERNAL MEMORY
ERROR
The configuration file is corrupted. Contact your supplier for
assistance.
7.10 Fault finding 3110
Unit is inoperative
Read/Write
configuration does not
operate
Check the DC supply.
Check reset button not tripped and reset if required.
Check 12V DC supply to module. If supply present but not operational try new
unit.
Check for loose wires on the DC connector plug and socket.
Check continuity on +VE and -VE wires to battery.
Unit shuts down
Check DC supply voltage is not above 16 Volts or below 9 Volts
Check the operating temperature is not above 70°C.
Check the DC fuse.
Unit locks out on
Emergency Stop
Check emergency stop switch is functioning correctly.
Check wiring is not open circuit.
Low oil Pressure fault
operates
after engine has fired
Check engine oil pressure.
Check oil pressure switch and wiring, switch is normally closed and opens
with pressure.
Check Oil level and fill to correct level if necessary
Check for loose wires on the Oil switch & DC loom connector block.
Check the continuity of the earth wire. (Refer to wiring diagram)
Check operation of Oil switch.
High engine
temperature fault
operates after engine
has fired.
Check engine temperature.
Check switch/sensor and wiring.
Check switch polarity is correct Normally closed.
Check for loose wires on the temperature switch & DC loom connector block.
Check the continuity of the earth wire. (Refer to wiring diagram)
Check operation of the temperature switch.
Check that the generator air inlets and outlets are not obstructed.
Shutdown fault
operates
Check relevant switch and wiring of fault indicated on LCD display.
Check configuration of input.
HZ / Frequency
shutdown &
Voltage
shutdown
Check reset button not tripped and reset if required.
Check AC Input at module. 115V or 230V (Dependant on type of generator)
Check engine speed is set to 52.5Hz at no load. Adjust if required (Speed
should be set when engine is cold)
Check AC supply from alternator. (If no output refer to alternator handbook)
Check fuse on AVR. (If fitted)
Check engine has been regularly serviced.
Warning fault
operates
Check relevant switch and wiring of fault indicated on LCD display.
Check configuration of input.
Fail to Start is
activated after pre-set
number of attempts to
start
Check wiring of fuel solenoid.
Check fuel lift pump operational & fuel supply to engine.
Check battery supply.
Check battery supply is present on the Fuel output of the module.
Check battery voltage is above 12.5V.
Check Oil level and fill to correct level if necessary.
Check fuel level.
Check operation of fuel lift pump.
Check fuel is reaching the injectors. When running correctly fuel should be
running freely from the injector return pipe. If no fuel running from return
check the fuel filters & check condition of fuel.
Check no air in system. Keep fuel pump running using prime button for 20-
30 seconds.
Starter Motor not
operating
Check Emergency stop.
Check the fuses.
Check battery voltage is above 12.5V.
Check for loose wires on the solenoid, relays, fuses, module terminals, plug

Issue 6 9 15/06/2015
and socket.
Check +VE supply from battery to starter motor.
Check -VE supply.
Check start terminal on Starter motor & trace back to battery via relay.
Check start terminal on Starter motor & trace back to module via relay, plug &
socket.
Ensure oil pressure switch or sensor is indicating the “low oil pressure” state
to the 3110 controller.
Fuel solenoid not
operating
Does the Fuel solenoid energise when the starter motor turns over.
Check Emergency stop.
Check the re-sets.
Check battery voltage is above 12.5V.
Check for loose wires on the solenoid, relays, fuses, module terminals, plug
and socket.
Check -VE supply.
Check +VE on Fuel solenoid & trace back to battery via relay.
Check +VE on Fuel solenoid & trace back to module via relay, plug & socket.
Continuous starting of
generator when in
AUTO
Check that there is no signal present on the “Remote Start” input.
Check configured polarity is correct.
Generator fails to start
on receipt of Remote
Start signal.
Check Start Delay timer has timed out. (Not configured on standard builds)
Check signal is on “Remote Start” input.
Confirm correct configuration of input is configured to be used as “Remote
Start”.
Check that the oil pressure switch or sensor is indicating low oil pressure to
the controller. The set will not start if oil pressure is not low.
Battery not
charging
Check for loose wires on charge alternator.
Check for loose wires on the DC connector plug and socket.
Check fuse. Fuse holder situated next to regulator in control panel.
Check continuity of all wires from charge regulator. (Refer to wiring diagram)
Check voltage at the battery while generator is running, voltage should be
13.4V - 14.4V.
Check AC voltage on green/white wires from engine voltage should be 38V.
Replace regulator.
Low fuel level
Check fuel level is at 1/3 a tank minimum.
Check level switch operation normally closed with low fuel, opens when fuel
level ok.
Check connections on level switch.
Engine runs but
generator will not take
load
Check MCB is switched on.
Check change over switch if fitted is switched to correct voltage.
Fail to stop alarm
when engine is at rest
Check low oil pressure switch is operating correctly.
Check engine is operating correctly.
Module appears to
‘revert’ to an
earlier configuration
When editing a configuration using the PC software it is vital that the
configuration is first ‘read’ from the controller before editing it. This edited
configuration must then be “written” back to the controller for the changes to
take effect.
When editing a configuration using the Front Panel Editor, be sure to press
the Save button to save the change before moving to another item or
exiting the Front Panel Editor.
Inaccurate generator
measurements on
controller display
The 3110 controller is true RMS measuring so gives more accurate display
when compared with an ‘average’ meter such as an analogue panel meter or
some lower specified digital multimeters. Accuracy of the controller is better
than 1% of full scale. Ie Gen volts full scale is 333V ph-n so accuracy is
±3.33V (1% of 333V).
NOTE:- The above fault finding is provided as a guide check-list only. For
further information http://www.deepseaplc.com/

Issue 6 10 15/06/2015
8 SERVICE AND MAINTAINENCE
IMPORTANT WARNING:
After any service on the generator, ensure that all piping and electrical cables are correctly
routed and secured away from hot parts. Failure to observe this warning may result in
damage to the piping and cables which could result in a fire.
Do not service or work on generator whilst the engine is running. Always disconnect
battery prior to working on engine or alternator.
8.1 Engine service
Service the engine strictly in accordance with the instructions given in the relevant
operator manual / handbook. An approved specialist must carry out any maintenance.
Any spare parts required should be of genuine manufacturer’s origin. Note: failure to
adhere to manufacturer’s recommended service schedules may invalidate the warranty.
Please consult engine operator’s manual for full service intervals.
8.2 Alternator service
Brushless alternators employed on Stephill Generators are maintenance free. Service
must be carried out by competent qualified personnel strictly in accordance with the
instructions given in the handbook. Any spare parts required should be of genuine
manufacturer’s origin.
9 Alternator spares
Part No
Alternator
Description
028-0026
NSM
Diode
037-0019
NSM
Capacitor - 35µf
10 Yanmar consumable spares
Part No
Description
029-0007
Air filter
029-0032
Oil filter
11 Spares (general)
Part No
Description
Qty
028-0036
Alternator NSM
1
029-0022
Engine L100
1
039-0015
Engine wiring loom
1
027-0013
Engine mount
2
027-0014
Alternator mount
2
027-0022
Wheel
2
027-0023
Wheel cap
2
022-1012
Filler cap
1
022-1003
50mm Fuel tank gasket
1
022-1004
Temperature switch
1
020-0128
Temperature switch plate
1
022-1015
Low fuel switch
1
022-1001
Neoprene door seal
3M
022-1017
Toggle latch strike
2
022-1018
Toggle latch
2
022-1002
Coverstay
1
022-1007
Wing head stud
6
022-1008
Retainer washer (wing head stud)
6
022-1009
Snap in housing (wing head stud)
6
022-1010
Wear washer (wing head stud)
6
018-0054
50mm Grommet
2
022-1021
50mm Air hose
0.5M
055-0006
Hours run meter
1
036-0039
MCB Cover
1

Issue 6 11 15/06/2015
Part No
Description
Qty
036-0009
Circuit breaker 20Amp 2pole
1
036-0049
Re-set button 16Amp
3
036-0052
Re-set button 30Amp
2
036-0056
Re-set button Dust cover
6
036-0050
Re-set button 20Amp
1
044-0001
Socket 115V 16Amp
2
044-0002
Socket 230V 16Amp
1
044-0003
Socket 115V 32Amp
1
044-0004
Socket 230V 32Amp
1
043-0021
Voltage selector switch
1
045-0012
Battery warning lamp
1
045-0013
Low fuel warning lamp
1
045-0016
Low oil warning lamp
1
045-0014
High engine temperature warning lamp
1
045-0001
Key switch
1
045-0017
Bulb
4
054-0009
Battery 12N24-3
1
056-0001
Relay-5pin 12V DC
3
022-0596
Fan adaptor
1
022-0614
Fan cowl
1
022-1035
Fan
1
022-1036
Fan locking ring
1
12 SE6000D4
Part No
Description
Qty
022-0536
SE6000D Silencer bracket
1
022-0563
SE6000D4 Silencer
1
022-0501
SE6000D4 Tail pipe
1
014-1004
Flush pull (Roof hand hold)
1
022-2002
SE6000D4 Control panel (wired)
1
022-0552
SE6000D4 Control panel (blank)
1
022-0562
SE6000D4 Fuel tank
1
048-0013
SE6000D4 Fuel filter
1
13 SSD6000
Part No
Description
Qty
022-0565
SSD6000 Manifold pipe
1
022-0566
SSD6000 Silencer
1
022-0569
SSD6000 Down pipe
1
022-0567
SSD6000 Tail pipe
1
022-0579
SSD6000 Fuel tank
1
022-1011
6mm Tee piece
2
022-2010
SSD6000 Control panel (wired)
1
022-0606
SSD6000 Control panel (blank)
1
022-1037
Facet fuel lift pump
1
045-0061
Deep Sea 3110 Module
1
045-0062
Deep Sea 3110 Gasket
1
048-0004
Fuel filter inline
1
022-1033
Flush pull (Roof hand hold)
1
14 SSD6000S
Part No
Description
Qty
022-0565
SSD6000S Manifold pipe
1
022-0566
SSD6000S Silencer
1
022-0580
SSD6000S Secondary Silencer
1
022-0569
SSD6000 Down pipe
1
022-0579
SSD6000 Fuel tank
1
022-1011
6mm Tee piece
2

Issue 6 12 15/06/2015
Part No
Description
Qty
022-2010
SSD6000 Control panel (wired)
1
022-0606
SSD6000 Control panel (blank)
1
022-1037
Facet fuel lift pump
1
045-0061
Deep Sea 3110 Module
1
045-0062
Deep Sea 3110 Gasket
1
048-0004
Fuel filter inline
1
022-1033
Flush pull (Roof hand hold)
1
15 WARRANTY
This generator supplied by STEPHILL GENERATORS LTD carries a warranty of 12
months from date of despatch or 2000 Hours.
During the warranty period, should the plant fail due to faulty design, materials or
workmanship by STEPHILL GENERATORS LTD or its sub-contractors, we undertake to
rectify the fault.
STEPHILL GENERATORS LTD will accept no responsibility whatsoever for equipment
that has failed due to;
- Operation with incorrect fuel, lubricating oil.
- Improper repair or use of parts not supplied by STEPHILL GENERATORS LTD.
- Lack of, or incorrect maintenance.
- Fair wear and tear, misuse, negligence, accidental damage, improper
storage, incorrect starting / warm-up / run-in or shutdown.
No warranty claim will be considered by STEPHILL GENERATORS LTD unless any
defective parts are available for inspection by us, or our nominees, to determine the
reason or cause of failure, and STEPHILL GENERATORS LTD is given the option of
repair or replacement.
STEPHILL GENERATORS LTD are not responsible for incidental or consequential
damages, downtime, or other costs due to warrantable failure, and unauthorised
alterations made to any product supplied by STEPHILL GENERATORS LTD.

Wiring updated to show plug and socket & dynamo.
Revision
STEPHI GENERATORS
Drawn
R GO DING
Drawing Number
SW11016
Phone [phone]
Fax [phone]
Description
100 WIRING E ECTRIC START
OP/HET/CHARGE FAI 15A F YWHEE
CHARGER
D
Issue
21/11/11
Dateast Number Used
20
DYNAMO
OI PRESSURE SWITCH
R3
FUE
SO ENOID
17 16
2.5mm
2.5mm
2.5mm
WHITE
OI PRESSURE
BATTERY CHARGE
STARTER MOTOR
R2
HIGH TEMPERATURE SWITCH (RS Part No 228-2260)
HIGH TEMPERATURE
R1
HIGH TEMPERATURE AMP
OI PRESSURE AMP
R2
16mm16mm
14
2
3
4
1
22
2 2
2
3 3
5 5
66
7
8
8
8
8
8
9
10
12
4
8
REGU ATOR
18
WHITE
14 20A
19
GREEN
YE OW
YE OW
WHITE
12
PUMP
3 8
FUE IFT
(OPTIONA )
1
2
5
4
3
14
20A RE-SET
1
FUE EVE
22 R1 15
FUE EVE SWITCH
15 8
R3
3
9
FUE EVE AMP
17 8
7
Note
All cable to be 1.5mm unless stated.
All cable except battery cable to be white.
3
16
10
2.5mm
Wire numbers added to regulator.
20/01/06
B
ucas key switch
POSITION
OFF
RUN
PRE HEAT
CRANK
21 3 4 5
Wiring changed numbers 11 & 14.24/09/08C
11
12 PIN P UG - SOCKET
11
2.5mm2.5mm
18 18
1919
GREEN / WHITE
GREEN / WHITE
18
19
4 4
15 15
5 5
6 6
3 3
11 Pin plug
viewed from rear
1 3
65 8
1918 15
4
3
11 Pin socket
viewed from rear
4 3
68 5
1915 18
1
3
11
WHITE / GREEN WHITE / GREEN
GREEN
REAR
P UG
3
3 3

New drawing.
Revision
STEPHILL GENERATORS
Drawn
R Golding
Drawing Number
SW 12072
Phone [phone]
Fax [phone]
Description
SE6000D NSM Dual voltage wiring
diagram 115V CTE / 230V Neutral bonded
& Single pole Re-Sets.
A
Issue
28/01/13
Date
Last Number Used
N/A
2.5mm Blue
2.5mm Brown
L
1.5mm Brown
1.5mm Black
115V 16A SOCKET
HRM
E
20A MCB
115V 16A SOCKET
LE
L
2.5mm Blue
NN
115V 32A SOCKET
E
N2.5mm Brown
2.5mm Blue
C/0 SWITCH
115 0 230
2B 1
6B
4B
5
3
8B 7
2A
6A
4A
8A
230V 16A SOCKET
E
NL
4.0mm Brown
Viewed from cable inlet
2.5mm Black 2.5mm Blue 2.5mm Brown 2.5mm Red
4mm Blue
E
NL
230V 32A SOCKET
BLUE
BROWN
RED
BLACK
Viewed from cable inlet
4.0mm Blue
2.5mm green/yellow
2.5mm Black
30A Re-Set
16A Re-Set
30A Re-Set 4mm Brown
2.5 Brown
16A Re-Set 2.5 Brown 16A Re-Set 2.5 Brown
4mm Brown
2.5mm Brown
2.5mm Blue
2.5mm Brown
NSM
Note
Links 4B - 6B & 4A - 8A are internal
GREEN
THIS IS NOT AN EARTH WIRE - 110V CENTRE TAP
Socket connector
Plug connector
2.5mm Blue
2.5mm Brown
2.5mm Red
2.5mm Black
2.5mm Red
2.5mm Black
2.5mm Brown
2.5mm Blue

21 3 4 5
6 7 8 10 11 1229
Item Part Number Description Qty
1 022-0687 SE6000D4 NSM Lifting beam 1
2 022-0585 SE6000D4 Engine door 2
3 022-0538 SE6000D4 Engine mounting bracket 1
4 022-0681 SE6000D4 NSM Trolley base 1
5 022-0537 SE6000D4 L100 Air inlet tube plate 1
6 022-0682 SE6000D4 NSM door 1
7 022-0614 SE6000D4 Fan cowl 1
8 022-0572 SE6000D4 Battery clamp bottom 1
9 022-0571 SE6000D4 Battery clamp top 1
10 022-0546 SE6000D4 Battery door 1
11 027-0022 Wheel 2
12 027-0023 Wheel cap 2
R Golding
A 04/02/13
New drawing
Date Revision Issue
THIRD
ANGLE
PROJECTION
Colour
Material
Description
Fax :
Phone :
Drawing Number
Drawn
SE6000D4 NSM Exploded view
22-696
Mild steel
N/A
STEPHILL GENERATORS
[phone]
[phone]
B Descriptions changed. 17/06/15

3 672 541
New part numbers added.26/05/06
C Descriptions changed.
Golding
A 08/11/04 New drawing
B
STEPHILL GENE ATO S
Date evision
Issue
P OJECTION
Description
Fax [phone]
Phone [phone]
Drawing Number
Drawn
SE6000D4 oof exploded view22-590 THI D
ANGLE
17/06/15
Item Issue Description
1 022-0590 SE6000D4 Dual voltage control panel
2 022-0583 SE6000D4 oof
3 022-0544 SE6000D4 Fuel tank support bracket large
4 022-0562 SE6000D4 Fuel tank
5 022-0544 SE6000D4 Fuel tank mounting bracket small
6 022-1012 Kelch cap
7 022-0119 SE6000D4 Fuel tank sealing gasket

Part No Description Qty
1 022-0627 SSD6000 Base 1
1 022-0675 SSD6000S Base 1
2 022-0607 SSD6000 Battery tray 1
2 022-0673 SSD6000S Battery tray 1
3 022-0576 SSD6000 Engine air inlet duct 1
4 022-0575 SSD6000 Battery door 1
5 022-0598 SSD6000 A le 1
6 027-0022 Wheel 2
7 027-0023 Wheel cap 2
8 022-0599 SSD6000 Trolley foot 2
9 022-0643 SSD6000 Handle right 1
9 022-0655 SSD6000 Light tower handle right 1
10 022-0642 SSD6000 Handle left 1
10 022-0654 SSD6000 Light tower handle left 1
11 022-0614 SSD6000 Fan cowl 1
12 022-0538 SSD6000 Engine mounting bracket 1
13 022-0697 SSD6000 NSM Alternator air inlet duct 1
14 022-0609 SSD6000 Lift beam 1
14 022-0677 SSD6000S Lift beam 1
15 022-1002 Stay 1
16 022-0666
SSD6000 Mark 5 Trolley foot brace
1
16/06/15
R Golding
A 04/02/13 New drawing
Date RevisionIssue
Descriptions updated.
[phone] PROJECTION
Colour
Material
Description
Fa :
Phone :
Drawing Number
Drawn
ANGLE
view
22-697
Mild steel
N/A
STEPHILL GENERATORS
[phone]
THIRD
SSD6000 & SSD6000S Base e ploded
B
3
16 41 2
5
15 12
8
910
13 14
6711