scheppach SG5200D Diesel Power Generator Instruction Manual

: June 12, 2024
: Scheppach

scheppach SG5200D Diesel Power Generator

scheppach SG5200D Diesel Power Generator

Explanation Of The Symbols On The Device

Symbols are used in this manual to draw your attention to potential hazards. The safety symbols and the accompanying explanations must be fully understood. The warnings themselves will not rectify a hazard and cannot replace proper accident prevention measures.

| Read the operating manual. Before using the device, always refer to the relevant section in the user manual.
---|---
| Important. Hot part. Keep your distance.
| Important. Always switch off the engine before refuelling . Do not refill during operation.
| Important. The exhaust gases are toxic. Do not operate the engine in areas that are not ventilated.
| Wear hearing protection. Excessive noise can result in a loss of hearing.
| Warning against electrical voltage
| Be very careful when dealing with fuels and lubricants!
| Remove the ignition cable before carrying out maintenance work and read the instructions.
| Do not expose the device to rain.
| Sparks are produced when the engine is started. These can ignite nearby flammable gases.
| Naked flames or smoking near the device is strictly prohibited!
| Do not expose to direct sunlight

Attention!

| We have marked points in these operating instructions that impact your safety with this symbol

Introduction

Manufacturer:
Scheppach GmbH
Günzburger Straße 69
D-89335 Ichenhausen
Dear Customer
We hope your new tool brings you much enjoyment and success.
Note:
In accordance with the applicable product liability laws, the manufacturer of this device assumes no liability for damage to the device or caused by the device arising from:

Improper handling,
Failure to comply with the operating instructions
Repairs carried out by third parties, unauthorised specialists.
Installing and replacing non-original spare parts
Application other than specified
Failure of the electrical system in the event of the electrical regulations and VDE provisions 0100, DIN 13 / VDE0113 not being observed

Please consider :
Read through the complete text in the operating manual before installing and commissioning the device. The operating manual is intended to help the user to become familiar with the machine and take advantage of its application possibilities in accordance with the recommendations.
The operating manual includes important instructions for safe, proper and economic operation of the device, for avoiding danger, for minimising repair costs and downtimes, and for increasing the reliability and extending the service life of the device. In addition to the safety instructions in this operating manual, you must also observe the regulations applicable to the operation of the device in your country. Keep the operating manual package with the machine at all times and store it in a plastic cover to protect it from dirt and moisture. They must be read and carefully observed by all operating personnel before starting the work.

The device may only be used by personnel who have been trained to use it and who have been instructed with respect to the associated hazards. The required minimum age must be observed.
In addition to the safety instructions in this operating manual and the separate regulations of your country, the generally recognised technical rules relating to the operation of such machines must also be observed.
We accept no liability for accidents or damage that occur due to a failure to observe this manual and the safety instructions.

Device Description

Push bar (3)
Fuel gauge (1)
Tank cover (2)
Transport hook (21)
Maintenance cover (5)
Casters (6)
Ignition lock (18)
Choke
Oil pressure warning light (8)
Voltmeter (9)
Selector switch 230V~ / 400V~ (11)
Safety trigger 400V~ (10)
400V socket (1x) (17)
Earth connections (14)
12V DC connection (15)
12V DC safety trigger (13)
230V socket (2x) (16)
Safety trigger 230V~ (12)
Battery attachment set (19)
Ring spanner (20)
Battery
Oil dipstick
Air filter
Brake lever (22)
Brake (23)

Scope of Delivery

Generator
Operating manual
Ring spanner
Battery attachment set
Battery 12V / 30AH

Proper Use

The machine may only be used in the intended manner.
Any use beyond this is improper. The user/operator, not the manufacturer, is responsible for damages or injuries of any type resulting from this. This power unit can power light bulbs, heaters, drills, water pumps, etc. Do not exceed the load limit specified for the power unit. The power unit may not be used to power devices that have a high power requirement.
The power unit cannot be used for precision devices such as computers. These precision devices may be damaged under certain circumstances by distortions caused by the broad wave when the power unit’s power is output. Do not connect the power unit to the electrical installation of a building.
An element of the intended use is also the observance of the safety instructions, as well as the assembly instructions and operating information in the operating manual. Persons who operate and maintain the machine must be familiar with it and must be informed about potential dangers.
In addition, the applicable accident prevention regulations must be strictly observed.
Other general occupational health and safety-related rules and regulations must be observed. The liability of the manufacturer and resulting damages are excluded in the event of modifications of the machine.

The machine may only be operated with original parts and original accessories from the manufacturer.
The safety, operating and maintenance specifications of the manufacturer, as well as the dimensions specified in the technical data, must be observed.

Only use the generator when in a technically faultless condition, appropriately and in compliance with the operating manual and with full knowledge of safety and hazards!
In particular, rectify malfunctions that could impair safety immediately (or commission rectification works accordingly)!
The safety, operating and maintenance specifications of the manufacturer, as well as the dimensions specified in the technical data, must be observed.
Relevant accident prevention regulations and other generally recognized safety and technical rules must also be observed.
The generator may only be used, maintained or repaired by persons who are familiar with it and have been informed of the dangers. The manufacturer shall not be liable for damage resulting from unauthorised changes to the machine.
The generator may only be used for the work for which it is built and which described in the operating manual.
The generator may only be operated with original accessories and original tools from the manufacturer.
Any use beyond this is improper use. The manufacturer is not responsible for the resulting damages; the user solely bears the risk.

Please observe that our equipment was not designed with the intention of use for commercial or industrial purposes. We assume no guarantee if the equipment is used in commercial or industrial applications, or for equivalent work.

Safety Information

This unit conforms to the prescribed safety regulations for electrical machines

Read the usage instructions carefully before starting the generator.
Improper use may lead to personal injury and damage to property. Persons who are unfamiliar with the instructions may not operate the unit. Store the user manual carefully.
Children and young persons may not use this unit.
The manufacturer does not take any responsibility for damage caused by improper use or changes to the machine.
Also adhere to the safety information, the assembly and operating instructions, as well as the accident prevention regulations that are generally applicable.

Important note :
Ensure that persons who work with this unit have read and understood these operating instructions before operating the unit.
Never use this unit inside buildings or in an environment that does not have ventilation.
The exhaust gases contain carbon monoxide, which is an odourless, poisonous gas.

Attention!
The voltage of the generator fluctuates; this may cause damage to the following devices:

Television sets, audio-video devices,
products or devices with electronic control

Safety information
Read this manual carefully – familiarise yourself with this device. Observe the instructions for use, restrictions and possible dangers that apply to this device.

Only set up the device on a firm surface.
The load must not exceed the power specified on the type plate of the generator. Overloading causes damage to the device or shortens the service life.
The engine may not be operated at an excessive speed. Operating the engine at an excessive speed increases the danger of injury. Parts that influence the standard speed must not be changed.
Devices with faulty or missing parts or without a protective housing or cover may not be operated. Information about spare parts can be obtained from your customer service.
Do not operate or store the device in a wet or damp environment or on highly conductive surfaces such as metal coating or steel structures. When operating the device under conditions such as those mentioned above, always wear rubber gloves and boots as well as an earth circuit breaker.
Keep the generator clean and free of oil, dirt and other foreign bodies.
Ensure that extension cables, power cables and all electrical components are in perfect condition. Never operate electrical devices with damaged or defective cables.
To prevent burns, do not touch the exhaust pipe and other engine and generator parts that heat up during operation.
Do not connect the device to household sockets.
Do not connect to other power sources.

Do not operate the generator under the following conditions:

When changing the engine speed
When decreasing the electrical power
When misfiring occurs
In the event of spark formation
In the event of excessive vibration
When flames or smoke occur
In enclosed spaces
When raining or in rough weather
In enclosed room sections
When raining or in rough weather
In the event of overheating in connected devices
In the event of damage to the sockets

Check the fuel system regularly for leaks and signs of wear such as rubbed or porous lines, loose or missing clamps and damage to the tank or tank cover. All faults must be remedied before operation.

The generator may only be operated, maintained and refilled under the following conditions:

Sufficient ventilation. Avoid environments in which steam can accumulate, e.g. trenches, cellars, excavations and bilges. Observe air flow and temperature. An ambient temperature of 40°C should not be exceeded.
In enclosed spaces, discharge hazardous exhaust gases via pipes. The engine exhaust gases contain carbon monoxide, a toxic, odourless and colourless gas that causes serious damage to health or death when inhaled.
Only refuel the generator when there is sufficient illumination. Avoid spilling fuel. Never refuel the generator during operation. Allow the engine to cool for approx. two minutes before refuelling.
Do not carry out fuelling in the vicinity of open flames, control lamps or spark forming electrical devices such as electrical tools, welding machines and grinding machines.
Check the silencers and air filters for perfect condition. These parts are used as flame protection in the event of backfires.
Do not smoke near the generators. Do not wear loose clothing, jewellery or similar objects which can get caught by the starter or other rotating parts.

The generator has been built according to the state-of-the-art and the recognised technical safety rules. However, individual residual risks can arise during operation.
Furthermore, despite all precautions having been met, some non-obvious residual risks may still remain.

Residual risks can be minimised if the “Safety instructions” and the “Proper use” are observed along with the whole of the operating instructions.

Dangers and protective measures
Exhaust gases:
Inhaling of exhaust gases
Only use the device outdoors

Burns:
Touching the exhaust pipe
Leave the device to cool down

Fire – explosion:
Diesel is flammable
Smoking is prohibited when refuelling and working

Warning! This power tool generates an electromagnetic field during operation. This field can impair active or passive medical implants under certain conditions.
In order to prevent the risk of serious or deadly injuries, we recommend that persons with medical implants consult with their physician and the manufacturer of the medical implant prior to operating the power tool.

Residual risks
The machine has been built according to the state-ofthe-art and the recognised technical safety requirements. However, individual residual risks can arise during operation.

Health hazard due to electrical power, with the use of improper electrical connection cables.
Furthermore, despite all precautions having been met, some non-obvious residual risks may still remain.
Residual risks can be minimised if the “Safety information” and the “Proper use” together with the operating manual as a whole are observed.
Keep your hands away from the work area, when the machine is in operation.

Technical Data

Generator AVR
Protection category IP23M
Continuous output Pnenn (S1) 3000 W at 230V~
4200 W at 400V 3~
Power Pmax (S2/5min) 3300W at 230V~
5000 W at 400V 3~
Rated battery voltage Unenn
230 V~
400 V 3~
12V DC.
Rated current Inenn
230V – 13A
400V – 7.6A
12V – 8.3A
Frequency Fnenn 50 Hz
Drive motor type 4-stroke air-cooled
Displacement 418 cm³
Max. power (engine) 5.7 kW
Fuel Diesel
Tank contents 16 l
Engine oil 1.65 l
Engine oil type 15W40
Consumption at ⅔ load approx. 1.43 l/h
Weight 145.9 kg
Performance class G1
Quality class B
Max. altitude (above mean sea level) 1000 m

Technical changes reserved!

Operating mode S1 (continuous operation)
The machine may be operated continuously with the specified power.
Operating mode S2 (short-term operation)
The machine may only be operated at maximum power for a brief time. Then, the machine must be brought to a standstill for a period of time so that it is not allowed to heat up.

Noise & vibration
Warning : Noise can have serious effects on your health. If the machine noise exceeds 85 dB (A), please wear suitable hearing protection.

Noise data
Sound power level LWA 96.2 dB(A) (EN ISO 3744)
Sound pressure level LpA 77 dB(A) (EN ISO 11201)
Uncertainty Kwa/pA 2.1 dB(A)

Unpacking

Open the packaging and carefully remove the device.
Remove the packaging material, as well as the packaging and transport safety devices (if present). Check whether the scope of delivery is complete.
Check the device and accessory parts for transport damage. In the event of complaints the carrier must be informed immediately. Later claims will not be recognised.

If possible, keep the packaging until the expiry of the warranty period.
Familiarise yourself with the product by means of the operating instructions before using for the first time.
With accessories as well as wearing parts and replacement parts use only original parts. Replacement parts can be obtained from your dealer.
When ordering please provide our article number as well as type and year of manufacture for your equipment.

ATTENTION!
The device and the packaging material are not children’s toys! Do not let children play with plastic bags, films or small parts! There is a danger of choking or suffocating!

Assembly / Before Commissioning

The device is preassembled at the factory!

Before commissioning

Connect the battery (fig. 5) Prepare battery and connect. Fit the battery (21) in the device using the battery attachment set (19). Now connect the red cable (+) and then the black cable (-) to the battery.

ATTENTION

Check before starting the engine:

Check the fuel level, refill if necessary – the tank should be at least half-full
Ensure the device has sufficient ventilation
Disconnect any connected electrical devices from the power generator
The condition of the air filter,
The condition of the fuel lines,
The firm seating of the external screw connections,

Attention! Fill the oil before first use.
Before each use, check the oil level with the engine switched off and on a level surface. Use the highest quality four-stroke oil or an HD oil with the same level of quality. SAE 15W-40 is recommended for general use at all temperatures.

Check the oil level (fig. 6 + 8)
Remove the maintenance cover (5). Remove the oil filler cap (22) and wipe the dipstick clean. Check the oil level by inserting the dipstick into the filling nozzle without screwing the cap on. If the oil level is too low, refill with the recommended oil up to the lower rim of the oil filling nozzle.
Device Description

Fill with fuel

In order to refuel the device, open the tank cover (3) by turning it anti-clockwise.
Fill storage tank with fuel
Close the tank by turning the tank cover (3) clockwise.

Recommended fuel
This engine only requires diesel.
Only use fresh, clean fuel.
Water or impurities in the diesel damage the fuel system.
Tank volume: 16 litres

Refuel in a well-ventilated area with the engine
stopped. If the engine was in operation immediately before, allow it to cool first. Never refuel the engine in a building where the diesel vapour may come into contact with flames or sparks.
Diesel vapour is highly flammable and explosive.
When handling fuels, you may suffer burns or other severe injuries.
• Switch off the engine and keep it away from heat, sparks and flames.
• Only refuel outdoors.
• Mop up spilled diesel immediately.

Electrical safety
Electrical supply lines and connected devices must be in perfect condition.
Only devices whose voltage information matches with the output voltage of the power generator may be connected.
Never connect the power generator to the mains (socket).
The power lines to the consumer must be kept as short as possible.

Environmental protection
Take any contaminated maintenance material and operating materials to a collection point designated for this purpose. Recycle packaging material, metal and plastic.

Earthing
Earthing the housing is necessary to discharge static charging. To do this, connect a cable to the earth connection of the generator (14) on one side and to an external earth (e.g. earthing rod) on the other side.

Start up

Starting the engine

Check whether the mechanical power selection switch: (a) is engaged in the correct position.
Important! The power selection switch is set at the factory and may not be changed.
Set the on/off switch (7) to the “ON” position using the key.
Pull the choke (8) and turn the on/off switch to “Start” using the key. Release the choke after approx. 5 seconds and the engine starts to run.
When the engine is running, turn the on/off switch back to the “ON” position.
If the engine does not start up immediately (especially after the tank was previously empty or after changing the diesel filter), repeat the start process by pulling the choke again.

Note: Some electrical devices (motorised jigsaws, drills, etc.) can have high power consumption if they are used under difficult conditions. Some electric devices (e.g. TV devices, computers, etc.) may not be operated with a generator. In case of doubt, check with the manufacturer of your device.

Overload protection
The power generator is equipped with overload protection. This deactivates the respective sockets in the event of an overload.

Attention! If this situation occurs, reduce the electric power that you are drawing from the power generator or remove defective devices that are connected.

Attention! Defective overload switches may only be replaced with identical overload switches with the same power data. Contact customer service for this.

12V DC connection:
The 12V DC connection (15) is switch off in the event on an overload. The 12V DC connection can be reactivated by pressing the overload switch (16).

230V~ sockets:
The 230V~ sockets (17) are switch off in the event on an overload. The 230V~ sockets can be reactivated by pressing the overload switch (18).

400V 3~ socket:
The 400V 3~ socket (13) is switch off in the event on an overload. The 400V 3~ socket can be reactivated by switching the overload switch (12) on.

If the selector switch (11) is on the left, the 230V~ sockets can be used.
If the selector switch (11) is on the right, the 400V 3~ socket is active.
The power generator is suitable for 230 V~ and 400 V 3~ AC voltage devices.
A 12V battery can be charged at the 12V DC connection (15). Use an adapter cable for this.
Attention! The power generator is not suitable for being connected to a house mains as an emergency power supply. It can cause damage to the generator or other electrical devices.

Shutting the engine off

Allow the power generator to run for a short time without load before switching it off so that the unit can “cool down”.
Set the on/off switch (7) to the “OFF” position using the key.

Oil warning indicator (9)
The indicator activates itself when the oil level is low and switches the engine off. As soon as the oil level is sufficient, the engine can be restarted.

Winter operation
As the generator is driven by a diesel engine, special measures must be taken for winter operation. The use of “winter diesel” is required if operating the diesel generator in outside temperatures of -3° to -10° Celsius.
The switchover of the diesel fuel to “winter diesel” takes place mainly at the end of October, differing from country to country. Ask your filling station about the time to switchover to “winter diesel”.

If the diesel generator is operated regularly, measures do not need to be taken as the switchover to “winter diesel” takes place automatically.
If the generator is not used for a long time in the autumn, but you want to reuse it in the winter, it is recommended to keep the tank almost empty.
Ask your filling station about the time to switch over to “winter diesel” and fill the tank with “winter diesel” before use in outdoor temperatures from -3° to -10° Celsius.
If, however, the diesel fuel “congeals”, the diesel generator must be brought into a room with temperatures of approx. +10° Celsius for approx. 12 hours.
If the tank is half full or full with normal diesel, then it must be emptied
The tank must then be filled with “winter diesel”.
If almost empty or up to half empty, it is sufficient to fill up with “winter diesel”.

Cleaning

We recommend that you clean the device directly after every use.
Clean the device at regular intervals using a damp cloth and a little soft soap. Do not use any cleaning products or solvents; they could attack the plastic parts of the device. Make sure that no water can penetrate the device interior.

Transport

WARNING
Before transport or parking indoors, allow the machine’s engine to cool down to avoid burns and risk of fire.
If you want to transport the device, empty the tank beforehand. Clean coarse dirt from the device using a brush or a hand brush.

Storage

Store the device and its accessories in a dark, dry and frost-free place that is inaccessible to children. The optimum storage temperature lies between 5 and 30 ˚C.
Store the power tool in its original packaging.
Cover the power tool to protect it from dust or moisture.
Store the operating manual with the power tool.

Maintenance

Oil change
The engine oil change should be carried out while the motor is at operating temperature.

Have a suitable container that will not leak ready for the oil change.
Remove the engine cover (5)
Open the oil filler plug (22)
Open the oil drain screw (c) and drain the warm engine oil into the collection container beneath the outlet drain.
Fill engine oil up to the top marking on the oil dipstick
Dispose of the used oil properly. Hand over your used oil at a collection point. Most filling stations, repair workshops or recycling centres take used oil back free of charge.

Air filter
Frequent cleaning of the air filter prevents carburettor malfunctions.

Clean the air filter and change the air filter inserts

The air filter must be cleaned every 30 operating hours.
Remove the engine cover (g)
Remove the air filter cover (h)
Remove the filter element (23)
Clean the filter element with soapy water, then rinse it with clean water and allow it to dry well before reinstallation.
The re-assembly takes place in reverse order

WARNING
Do NOT use petrol or cleaning solvents with a low flash point to clean the air filter element. This could result in fire or explosion.

NOTE
Never run the engine without an air filter or with a damaged air filter. This would allow dirt into the engine, which would result in severe damage to the engine. In this case, the seller and the manufacturer disassociate themselves from any warranty claims.

Changing the diesel filter (fig. 7)

The diesel filter must be changed when the inside of the filter is contaminated or impurities can be seen. In order to change the filter and collect diesel in the tank, a funnel and an empty diesel container are required.

Undo the metal bracket on both sides of the filter. Immediately insert the fuel hose through the funnel into the diesel canister and observe the diesel flow until no diesel drains. Remove the filter with impurities and throw it away. Install a new filter.

Emptying the tank

In order to empty the tank, first proceed as you would when “Changing the diesel filter”.
After removing the diesel filter, lead the diesel fuel from the tank via the funnel into the diesel canister. (ATTENTION: Ensure that the diesel canister is large enough to collect the remaining fuel in the tank!).
After draining is complete, carry out assembly as described under “Changing the diesel filter”.

Please provide the following information in the event of any enquiries:

Data of machine type plate
Data of motor type plate

Important note in the case of repairs:
When returning the device for repair, please ensure for safety reasons that it is free of oil and fuel when it is sent to the service centre.

Service information
With this product, it is necessary to note that the following parts are subject to natural or usage-related wear, or that the following parts are required as consumables.
Wearing parts*: Air filter, diesel filter, battery, injection nozzle

may not be included in the scope of supply!
Spare parts and accessories can be obtained from our service centre. To do this, scan the QR code on the cover page.

Disposal and recycling

The device is supplied in packaging to avoid transport damages. This packaging is raw material and can thus be used again or can be reintegrated into the raw material cycle.
The device and its accessories are made of different materials, such as metals and plastics. Take defective components to special waste disposal sites. Check with your specialist dealer or municipal administration!

Old devices must not be disposed of with household waste!
This symbol indicates that this product must not be disposed of together with domestic waste in compliance with the Directive (2012/19/EU) pertaining to waste electrical and electronic equipment (WEEE). This product must be handed over at the intended collection point.
This can be done, for example, by returning it when purchasing a similar product or delivering it to an authorised collection point for the recycling of old electrical and electronic devices. Improper handling of waste equipment may have negative consequences for the environment and human health due to potentially hazardous substances that are often contained in electrical and electronic equipment. By properly disposing of this product, you are also contributing to the effective use of natural resources. You can obtain information on collection points for waste equipment from your municipal administration, public waste disposal authority, an authorised body for the disposal of waste electrical and electronic equipment or your waste disposal company.

Do not throw primary batteries or rechargeable batteries away with household waste
Symbols As the consumer you are required by law to bring all batteries and rechargeable batteries, regardless whether they contain harmful substances or not, to a collection point run by the local authority or to a retailer, so that they can be disposed of in an environmentally friendly manner.
marked with: Cd = cadmium, Hg = mercury, Pb = lead

Troubleshooting

The following table shows fault symptoms and describes remedial measures in the event of your machine failing to work properly. If you cannot localise and rectify the problem with this, please contact your service workshop.

Fault	Possible cause	Remedy
Engine cannot be started	Automatic oil shut-off reacts (red LED	Check oil

level, fill with engine oil
No diesel fuel| Top up diesel fuel
Mechanical circuit breaker unlocked| Slide mechanical circuit breaker to the right
Diesel filter blocked| Clean or replace diesel filter
Air filter blocked| Clean or replace the air filter
Diesel fuel “congealed” due to low outdoor temperature| Proceed as described under “Winter operation” section
Fuse defective| Change defective fuse
Generator has insufficient or no voltage| Controller or capacitor defective| Contact the specialist dealer
Overload protection switch triggered| Reduce consumption
Air filter dirty.| Clean or replace filter
Battery is not charged| Fuse defective| Change defective fuse

Spare Parts

Spare Parts

Spare
Parts

CE Declaration of Conformity

Scheppach GmbH, Günzburger Str. 69, D-89335 Ichenhausen

hereby declares the following conformity under the EU Directive and standards for the following article

Brand: Scheppach
Article name: DIESEL-STROMGENERATOR – SG5200D
DIESEL POWER GENERATOR – SG5200D
GROUPE ÉLECTROGÈNE DIESEL – SG5200D
Art. no.: 5906222903

CE Declaration of Conformity

Standard references:
EN ISO 8528-13:2016; EN 60204-1:2006/A1:2009; EN 55012:2007+A1; EN61000-6-1:2007

This declaration of conformity is issued under the sole responsibility of the manufacturer.

The object of the declaration described above fulfils the regulations of the directive 2011/65/EU of the European Parliament and Council from 8th June 2011, on the restriction of the use of certain hazardous substances in electrical and electronic equipment.

Ichenhausen, den 20.12.2021
CE Declaration of Conformity

First CE: 2019
Subject to change without notice

Documents registrar: Viktor Härtl
Günzburger Str. 69, D-89335 Ichenhausen

Warranty

Apparent defects must be notified within 8 days from the receipt of the goods. Otherwise, the buyerís rights of claim due to such defects are invalidated. We guarantee for our machines in case of proper treatment for the time of the statutory warranty period from delivery in such a way that we replace any machine part free of charge which provably becomes unusable due to faulty material or defects of fabrication within such period of time. With respect to parts not manufactured by us we only warrant insofar as we are entitled to warranty claims against the upstream suppliers. The costs for the installation of the new parts shall be borne by the buyer. The cancellation of sale or the reduction of purchase price as well as any other claims for damages shall be excluded.

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