and DHY8000SE(LR) User Manual
Contents
1. Q 1 12eju02 Aejay p esnJ 1013009 1135 SLY ZT e 931eJe81 ones 191328 ACT CD VCE ASIT 199905 ee ili 9 8uts VC AO C a se lt gt 194205 SJeyeeJg 1In2JI N B Subject to change without prior notice 11 1 Page 19 HYUNDAI 12 SERVICE RECORD SHEET Date Hours Maintenance undertaken Name Page 20 HYUNDAI Page 21 HYUNDAI 13 GENPOWER CONTACT DETAILS 13 1 Postal address Genpower Limited Isaac Way Pembroke Dock Pembrokeshire SA72 4RW UK 13 2 Telephone and Fax contact numbers Office 44 0 1646 687880 13 3 Email contact Technical service genpower co uk 13 4 Web site www hyundaipowerequipment co uk Page 22 HYUNDAI 14 DECLARATIONS OF CONFORMITY 14 1 Genpower Ltd confirms that these Hyundai products conform to the following Directives 14 1 1 2006 42 EC Machinery Directive 14 1 2 2004 108 EC EMC Directive 14 1 3 2000 14 EC Noise Emissions Directive 14 1 4 97 68 EC NRMM Emissions Directive 14 1 5 2006 95 EC Low Voltage Directive EC DECLARATION OF CONFORMITY The undersigned as authorised by Genpower Ltd Declares that the following equipment manufactured under licence by Hyundai Corporation Korea Conforms to the Directive 2000 14 EC as amended Of the European Parliament and of the council on the approximation of the laws of the Member States relating to the noise emissi2. HYUNDAI DIESEL GENERATOR 3000rpm Models DHY6000SE LR DHYSOOOSE LR HYUNDAI User Manual Licensed by Hyundai Corporation Korea 10 11 12 13 14 Section Description SAFETY MACHINE LAYOUT PREPARATION for STARTING OPERATING THE GENERATOR LOAD STOPPING THE MACHINE PERIODIC MAINTENANCE LONG TERM STORAGE TROUBLE SHOOTING SPECIFICATIONS WIRING DIAGRAM SERVICE RECORD SHEET GENPOWER CONTACT DETAILS DECLARATIONS OF CONFORMITY HYUNDAI Page N N 5 5 12 13 13 14 14 15 15 16 16 17 18 19 20 21 22 Page 2 HYUNDAI 1 SAFETY AL A 1 1 The operator of the machine is 1 1 1 Responsible for and has a duty of care in making sure that the machine is operated safely and in accordance with the instructions in this user manual 1 1 2 Should never be left it in a condition which would allow an untrained or unauthorised person s to operate this machine 1 1 3 All due care and diligence should be taken by the operator for the safety of and with regard to those around whilst using the machine to include but not limited to 1 1 3 1 Elderly children pets livestock and property 1 2 Some or all of the following PPE Warning Signs and symbols may appear throughout this manual and you must adhere to their warning s Failure to do so may result in personal injury Personal Protective clothing PPE Warning Signs an
3. DB T E e i DE M cC TEIE X 55 eo Ae LE US LL ate o Page 7 HYUNDAI j 4 Function Display Starter Switch 110 VAC to 230 VAC Changeover Switch JIGITAUPAN m Emergency STOP 4 OFF AC230V OF NY NY F i A Outlet F 12 VDC 8 3A Outlet In EMERGENCY Pull down to utiet Fuse utle gt 4 mp STOP machine AC115V AC115V 4 Dipstick and oil Main Earth Point filling ca ATS ey CEIRSIEC OD PU M n 2 say C va 7 d Oil drain bolt 2 5 a L ee 1 n 82 I a 3 PREPARATION for STARTING WARNING e DO NOT refill tank while engine is running or HOT e not smoke or allow flames or sparks in the area where the engine is refuelled or where the fuel is stored e Do not overfill the diesel tank and make sure the filler cap is securely closed after refuelling e Take care not to spill fuel when refuelling If any fuel is spilled make sure the area is clean and dry before starting the engine CAUTION Wear suitable PPE suggested but not limited too QOO 3 1 Selection and handling of fuel 3 1 1 Selection of fuel 3 1 1 1 Only use standard specification diesel this can be red or white 3 1 1 2 Keep dust and water out of the fuel 3 1 1 3 When filling the fuel tank from drums m
4. 9 1 Always fuel and defuel in well ventilated area 1 4 9 2 Always wear correct suitable and fit for purpose Personal Protective Equipment PPE suggested items are as follows but are not limited too Hand protection 1 4 9 4 Protective clothing 1 4 9 5 Respiratory protective equipment should be used when in an unventilated area 1 4 9 6 When defueling always use a propriety fuel retriever 1 4 9 7 Always carry fuel in the correct and clearly marked container 1 4 10 Electrical Safety 1 4 10 1 Electricity can kill never work on LIVE ENERGISED equipment 1 4 10 2 Identify electrical isolation method and always isolate all electrical supplies prior to carrying out any maintenance work 1 4 10 3 Prior to use and with all electrical supplies isolated check all electrical cables plugs and connections for the following 1 4 10 3 1 Are intact and have no signs of damage to include but not limited to bare wires chaffing cuts and loose wiring If there are any signs of damage the damaged item should be taken out of service until the damage has been repaired by an electrically competent person 1 4 10 4 All trailing cables should be routed so as not to cause any kind of trip hazard 1 4 9 3 Page 5 HYUNDAI 1 4 10 5 Never work on or near electricity with wet hands wet clothing and wet gloves 1 4 10 6 Batteries present a risk if they become damage by the possible leaking of electrolyte This ele
5. API CH 4 CF SJ SL diesel engine oil or higher grade 8 LONG TERM STORAGE WARNING e After running the engine the oil will be very hot e Wear correct PPE minimum of gloves and overalls an LES 8 1 If storing the generator for long periods of time make the following operations 8 1 1 Operate the engine for 10 minutes and then stop 8 1 2 Stop the engine 8 1 3 Drain the engine oil whilst the engine is still warm and refill with fresh oil 8 1 4 Turn the engine for 2 3 seconds with the decompression lever set at the non compression position and the starting key set at the START position Do not start the engine 8 1 5 Wipe off the oil and dirt from the engine and store in a dry place Page 16 HYUNDAI 9 TROUBLESHOOTING 9 1 Troubleshooting all corrective actions should be carried out by suitably qualified person s possible faut eause The governer lever is not at START position Set lever to S position activated depressed button Fuel injection pump does not deliver fuel or delivers The Diesel engine will not insufficient fuel start The specified oil level should Check the engine oil level be to the upper lever The injector has severe carbon build up Check battery performance The start motor turns slowly and all connections Charge or replace with a new Remove the injector pump and have it tested Clean the injector The battery is flat one been tur
6. Lever position 6 5 Or press or pull down the stop lever Pull down to STOP machine 7 PERIODIC MAINTENANCE A WARNING Ensure the engine is off before performing any service e fthe engine must be run make sure that the area is well ventilated e The exhaust contains poisonous carbon monoxide gas 7 1 Maintenance chart All work s should be carried out by a competent person if you need technical advice contact Genpower Every year or 1000 Check and refill with diesel Y Check and refill with engine oil Y Check for oil leakage CY Check and tighten fastening parts Ye Replace engine oil NENNEN NN NENNEN Check battery condition Check carbon brushes and slip rings Yes Yes Yes Yes es Y NENNEN NENNEN _ NENNEN NEN Page 15 HYUNDAI 7 2 Replacing engine oil CAUTION After engine has been run prior to changing the oil will be very hot Wear correct PPE minimum of gloves and overalls umm A CAUTION DO NOT allow any dust dirt or any other debris enter oil or crankcase 7 2 1 Remove the oil filler cap 7 2 2 Remove the drain plug and drain the old oil while e E Dipstick and oil filling cap the engine is still warm 7 2 3 The plug is located on the bottom of the cylinder block 7 2 4 After draining re tighten the drain plug and refill OB M p with the recommended oil
7. ake sure that no dust or water is mixed in with the fuel This can cause serious damage to the fuel injection pump or the injector nozzle 3 1 1 4 Do not overfill Overfilling can potentially be very dangerous Diesel can expand in hot weather and overflow 3 1 1 5 Always leave a 25mm gap above the fuel level WARNING e Always check the engine oil level with the generator on a flat level surface before starting or refilling the machine Page 8 HYUNDAI A CAUTION Wear suitable PPE suggested but not limited too n3 Em Em 3 2 e fan insufficient amount of engine oil is used damage to the engine may result e Donot overfill the engine with oil e This generator is equipped with a low oil pressure switch this system will stop the engine automatically when the oil pressure falls below the minimum pressure required e This helps prevents damage such as bearing seizures etc However this should not be relied upon and the engine oil level should be checked and topped up if required daily Check and refill the engine oil 3 2 1 To ensure the generator maintains an optimum performance and the life of the generator is as long as possible it is important to use the correct engine oil SAE10W 30 s Pe SAE15W 40 API CH 4 CF SJ SL diesel engine Dipstick and oil oil or higher grade and change after the first 20 hours then every 100 hours E 3 2 2 If the correct engine oil is not used or the oil drain bolt engine o
8. an caravan motorhome or boat EVEN doors windows vents and hatches are open Only use OUTDOORS and as far away from doors windows vents and open hatches as possible to prevent inhaling fumes READING MANUAL BEFORE USE WILL HELP AVOID OTHER MACHINE HAZARDS TOXIC FUMES 1 4 General fuel safety 1 4 1 Fuel Safety additional information can be obtained from the Health and Safety Executive HSE document SR16 CAUTION 1 4 2 fuels are Flammable 1 4 3 Keep away from all ignition sources i e Heaters Lamps sparks from Grinding or welding 1 4 4 Hot work on tanks that have contained fuel is extremely dangerous and should not be carried out 1 4 5 Keep work area clean and tidy 1 4 6 Clean up all spills promptly using correct methods i e absorbent granules and a lidded bin Page 4 HYUNDAI 1 4 7 Dispose of waste fuels correctly 1 4 8 Diesel safety 1 4 8 1 Always fuel and defuel in well ventilated area 1 4 8 2 Always wear correct suitable and fit for purpose Personal Protective Equipment PPE suggested items are as follows but are not limited too Hand protection 1 4 8 4 Protective clothing 1 4 8 3 1 4 8 5 Respiratory protective equipment should be used when in an unventilated area 1 4 8 6 When defueling always use a propriety fuel retriever 1 4 8 7 Always carry fuel in the correct and clearly marked container 1 4 9 Petrol safety 1 4
9. ctrolyte is an acid and can cause serious injuries Care should be taken when working on or near them 1 4 10 6 1 Should you come into contact with acid you should 1 4 10 6 1 1 Remove all clothing contaminated with acid 1 4 10 6 1 2 Get medical assistance as soon as possible 1 4 10 6 1 3 Use fresh running water to wash off excess acid continue this until medical assistance arrives 1 4 10 6 1 4 If acid come into contact with Eyes the acid needs to be immediately washed away Make sure that you do not wash the acid to another part of the face or body 1 4 10 6 1 5 Gasses from charging batteries are highly flammable and great care should be taken to charge in well ventilated areas 1 5 Additional Safety guidelines 1 5 1 Exhaust and Engine 1 5 1 1 The engine and exhaust will become very hot during use do not touch 1 5 1 2 These items remain hot for some time after use 1 5 1 3 Place the machine an area where pedestrians or children are not likely to touch the machine 1 5 1 4 Avoid placing any flammable materials near the exhaust outlet during operation 1 5 1 5 Keep the machine at least 1 m from buildings or other equipment or the engine may overheat 1 5 1 6 Avoid operating the engine with a dust cover 1 5 2 Control Functions 1 5 2 1 Oil Warning System 1 5 2 1 1 When the pressure switch senses low oil pressure engine will stop automatically 1 5 2 1 2 Unless you refill with oil the engine will not s
10. d Symbols HOT SURFACE SHOCK EXPLOSION MOVING PARTS EE mE m Page 3 HYUNDAI A D 1 3 Carbon Monoxide 1 3 1 Carbon monoxide is a colourless and odourless gas breathing this gas It can cause death as well as serious long term health problems such as brain damage 1 3 2 The symptoms of Carbon monoxide poisoning can include the following 1 3 2 1 Headaches Dizziness Nausea Breathlessness Collapsing or Loss of consciousness 1 3 2 2 Carbon monoxide symptoms are similar to flu food poisoning viral infections and simply tiredness That s why it s quite common for people to mistake this very dangerous poisoning for something else 1 3 3 To avoid Carbon monoxide poisoning DO NOT Use Petrol Diesel powered equipment inside a home or garage even if doors and windows are open 1 3 4 If you think you or someone around you has been affected by carbon monoxide poisoning 1 3 4 1 Get fresh air immediately 1 3 4 2 Open doors and windows turn off machine and leave the affected area 1 3 4 3 See your doctor immediately or go to hospital let them know that you suspect carbon monoxide poisoning 1 3 5 DO NOT use in an enclosed area or a moving vehicle DANGER BREATHING IN CARBON MONOXIDE zi FUMES CAN KILL YOU To help protect against CO poisoning install a Carbon Monoxide detector Qr ia Bg 39 NEVER use Petrol Diesel powered equipment inside especially a home garage tent camper v
11. il is not replaced every 100 hours as required the risk of crankshaft bearing failure piston seizure piston ring sticking and accelerated wear of the cylinder liner main bearing and failure of other moving components increases significantly The generator lifespan will be greatly reduced if oil level and oil changes are reduced Oil Dipstick 3 2 3 Remove oil filler cap and check engine oil level 3 2 4 If oil level is below the lower level line refill with SAE API CH 4 CF SJ SL diesel engine oil on dipstick or to the top of filler neck N B do not screw oil filler in the oil filler cap when checking oil level 3 2 5 Change contaminated oil _ Upper Level 3 3 Service the Air Cleaner WARNING e Do not wash air filter with detergent Page 9 e Replace the air filter if the engine output decreases or excessive exhaust smoke is noticed e Never run the generator without the air filter otherwise rapid engine wear will result 3 3 1 Remove the access panel to reveal air filter cover 3 3 2 Undo the nut anti clockwise and remove the air cleaner cover and take out the element 3 3 3 Clean the air filter 3 3 4 Reattach the air filter EA cover and screw on the bolts nut HYUNDAI filter behind panel these four 3 4 Checking the Generator before start up WARNING CAUTION e Be sure to turn off the main breaker switch before starting The generator
12. ned ON ON position producing power not good inserted into sockets The rated sped is too HIGH or Adjust engine speed to too LOW produce 52 Hz with no load AVR is damaged Replace AVR Page 17 HYUNDAI 10 SPECIFICATIONS Model DHY6000SE DHY6000SE LR DHY8000SE DHY8000SE LR Continuous a Power 4 5 kW 5 5 kW HT Voltage AC Volts 115VAC 230VAC 16 2 115V 2 230V Fuel Tank 1 capacity Litres DC Output Volts 12V 8 3A Amps Engine Hyundai D400 Forced Air Hyundai D500 Forced Air B cooled OHV cooled OHV Power Output HP 10 HP 12 HP Start method Speed 3000 rpm Lubrication Oil SAE 10W 30 or 15W 40 API CH 4 CF SJ SL diesel engine oil grade or higher Lubrication Oil Capacity Litres el 1 COS Voltage Automatic Voltage Regulation A V R Regulation Nett Weight KG Weight Dimensions Dimensions Lx 935 x 520 x 935 x 545 x 935 x 520 x 935 x 545 x W x H mm 765 835 765 835 Page 18 HYUNDAI 11 WIRING DIAGRAM plousjos uuej v eunsseJd 8 lanj YTOZ 1200120 p aluelS Aq peonpouday AOEZ ASTT Y13S0008AHQ 8 3S0009AHQ 104 SuIMe1Q S 2S 1O JE1BUIYN asaig 00000000 __ J0 e1n59 3115 INS Jalloquo5 I e ID ws 10 OW O us 1 1 Q SLY 8 4 7 Aualleg asnj 1941045 D do1s 3 TH
13. oads with the largest motor first then the smaller items 5 1 5 If the generator is overloaded the main breaker will trip 5 1 6 To reset the breaker do the following 5 1 6 1 Turn OFF and disconnect all loads 5 1 6 2 Reset breaker and add load onto the circuit to within 5096 to 7596 of rated output 5 1 7 Wait a few minutes before resuming operation 5 2 Electrical appliances particularly motor driven equipment will have a very high start up current The table below provides reference for connecting these appliances to the generator Typical Exampe Pe Starting Rated appliance Appliance Starting Rated Lighting Incandescent Incandescent lamp or heating lamp 1000 100 vA 100 vA appliance watts Fluorescent FI 40 to 60 X 2 x1tox1 5 Fluorescent Lamp 80 VA Lamp Lamp VA Motor Refrigerator Driven x3 5 xito Electric fan Refrigerator 150 450 to 750 150 to 30 Compressor or watts VA VA Equipment Binder 6 STOPPING MACHINE WARNING e not stop the engine suddenly or whilst under load e This can damage the AVR and cause damage to the alternator through overheating e Donot stop the engine with the decompression lever Page 14 HYUNDAI 6 1 Switch OFF equipment connected to the generator 6 2 Turn off the main breaker switch 6 3 Run the generator without load for three minutes 4 6 4 Turn the electric key start switch to the OFF RUN
14. on in the environment by equipment for use outdoors Equipment Category Generator Product Name Model DHY amp GOQQSE LR DHYSOOQSELR Type Serial Ma Silenced diesel generator Electric Power DHY6000SE LR 5 2 KW DHYS8000SELR 6 0 KW The technical documentation is kept by Roland Llewellin Genpower Ltd Isaac Way London Road Pembroke Dock 5 72 4RW Pembrokeshire 5A73 2R5 United Kingdom The conformity assessment procedure followed was in according with annex VI of the Directive Notified Body European Certifying Organisation Via Mengolina 33 Faenze 48018 Italy Certification N N714F09351011 Measured Sound Power Level 96d B A Guaranteed Sound Power Level 96dB A copy of this certificate has been submitted to the European Commission and to EU Member State United Kingdom Place of Declaration Pembroke Dock Date 28 06 2013 Signed by Roland Llewellin Position in Company Director Name and address of manufacturer or Authorised representative Roland Lleveellin I2 C faire LA Genpower Ltd Isaac Way London Road Pembroke Dock 5472 4RW Pembrokeshire 5A72 4RW United Kingdom Page 23 GENPOWER LTD Isaac Way London Road HY Li DAI Pembroke Dock UNITED KINGDOM SA72 ARW T 44 0 1646 687 880 F 44 0 1646 686 198 E info hyundaipowerequipment co uk www hyundaipowerequipment co uk
15. ry must be charged 3 6 1 3 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 6 1 4 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 3 6 1 5 Make sure that all battery acid spills are correctly cleaned up straight away 3 6 1 6 The battery should be stored in a charged condition 3 6 1 7 The battery isa 12 volt 36Ah sealed lead acid battery and requires maintenance other than 3 6 1 7 1 Ensure battery terminals are 3 6 1 7 2 Kept clean 3 6 1 7 3 Kept tight 3 6 1 7 4 Covered to prevent short circuiting 3 6 1 8 If the battery voltage is too low it will require charging before use 3 6 1 9 Keep the battery in a cool dry place It is important to clean the battery every three months and charge every six months HYUNDAI 4 OPERATING THE GENERATOR A CAUTION e Do not loosen or readjust either the engine speed limiting bolt or the fuel injection limiting bolt as this will cause the performance of the generator to be affected 4 1 Starting 4 1 1 Turn the main AC switch to the OFF position 4 1 2 Make sure that the machine has fuel for the task 4 1 3 Make sure the emergency STOP switch is out STOP RUN Lever turn anti clockwise 4 1 4 Set the engine speed lever is
16. set to RUN 4 1 5 Turn the starting key clockwise to the START position 4 m 4 1 6 Remove your hand from the key as soon as the lt engine starts 4 1 7 If the engine does not start after 10 seconds wait 15 seconds before trying again Excessive start attempts will cause the battery to flatten 4 1 8 If it does not start after 3 attempts or runs intermittently with excessive smoke check that the fuel system is fully primed 4 1 8 1 Priming before starting to prime make sure that there is fuel in tank and that you can contain any fuel spilt 4 1 8 1 1 It is done by releasing 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 4 1 8 1 2 When fuel appears replace pipe onto the injector pump and replace clip Clear up any fuel spills before restarting 4 1 8 1 3 The above may be necessary when new or if the machine runs out of fuel Page 12 HYUNDAI Towel to collect spilt fuel Injector pump inlet No fuel Fuel showing 4 1 9 Always leave the key in the ON position whilst the engine is running 4 1 10 Run machine for two minutes before applying load 4 1 11 Insert the plug into the socket you are about to use 4 1 12 Turn the main AC switch to the ON position and turn the electrical appliance ON A CAUTION e If the engine has been running the muffler will become very hot Be caref
17. should be earthed to prevent electric shocks e Turn off the main breaker switch and remove all loads e Before starting the engine be sure to switch OFF any appliances connected to it e Ensure that the breaker switch is OFF before switching between 115v 230v 3 5 Running in periods of Operation 3 5 1 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 3 9 LL 3 9 1 4 3 9 1 3 3 5 1 4 3 9 1 5 Warm up the engine 5 minutes after the initial starting before applying load Avoid applying loads above 3kw during the first 20 hours of operation It is important to replace the engine oil on time Replace the engine oil whilst the engine is warm after 20 hours running Ensure that old engine oil is drained out completely After first 20 Hours Every 12 months or 100 Hours or whichever is soonest Page 10 HYUNDAI 3 6 Battery A WARNING e connect tools or any other appliances to the generator before starting A CAUTION e Explosive gases are given off when charging battery Only charge in a well ventilated area away from sparks and naked flames 3 6 1 Battery Page 11 3 6 1 1 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 3 6 1 2 Using a voltmeter check the voltage is 12 3V if lower the batte
18. tart again 1 5 3 Starter Switch SW 1 5 3 1 The engine starter switch controls the ignition 1 5 3 2 Inthe OFF Position the ignition circuit is switched off and the engine will not run START 1 5 3 3 In the ON position the engine is ready for starting mos d 1 5 3 4 In the START position pushed against spring STARTER SW tension the starter motor is engaged and the machine will start Page 6 HYUNDAI 1 5 4 AC Switch Breaker 1 5 4 1 The AC Switch Breaker will turn OFF automatically when the load exceeds the generator output 1 5 4 2 If AC switch turns OFF then before resetting remove some of the load and keep below the rated output of the machine 1 5 5 DO NOT Connect the generator to Mains AC sockets in your building commonly known as back feeding it is extremely dangerous and illegal 2 MACHINE LAYOUT 5 Access Panel ot Open here z3 Vent grille Pe N E F ye a ca t _ st Le e 71 a V Los y E AM 4 ASYA e Maas fr M P AN Cast T 1 gt gt o9 Le gt So is e D d M i Pom tur gt r CN SLT 0T URNA Ad ed p E AX br m 1 gt 4 7 Ca ON mr _ 2 gt t aW A Z f _ 2 a da ETES Engine STOP RUN lever 4
19. ul not to touch the muffler until it has had time to fully cool down e Never refuel the fuel tank whilst the engine is still running 4 2 Checks whilst generator is running 4 2 1 After each use make sure that there are no abnormal sounds or vibration 4 2 2 Check that the engine is running smoothly normally 4 2 3 Check that there is no excessive smoke form the exhaust after 10 minutes of running and the engine has reached working temperature 4 2 4 Check that there are no oil or fuel leaks A NOTE e fyou notice any of the above stop the engine and locate the fault e Please contact Genpower for assistance if required 5 LOAD A CAUTION e Start appliances one by one 5 1 230 Volt AC use 5 1 1 After switching ON the main breaker switch and the engine running check the Voltage reading when in Voltage Mode It should read 230v 5 50Hz 5 1 2 The Digital panel only becomes active when the Main breaker is in the ON position The following will be displayed by successive presses of the M or mode button Page 13 HYUNDAI Voltage mode Frequency mode ees Lamp Illuminated Indicating Dow Voltage sew HYUNDAI Frequency Event timer or current running time hours This will reset to zero when main Breaker is OFF Total Run Time Volt Meter MY 3016 HE 5 1 3 Connect the equipment to the generator in correct order 5 1 4 Connecting the l
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