USER MANUAL DIESEL HYUNDAI DHY12000SE
Contents
1. 3 CHECR BEFORE USE 3 2 Preparation before starting 3 2 1 Selection of the fuel Only use light diesel Fill in the diesel to fuel tank at full level If the water exists in the diesel should drain off the water from oil water separator Otherwise the water will enter into fuel pump resulting in the engine to be damage FUEL TANK CAPACITY 211 Note Clean overflow diesel It is not permitted to smoke or stay close to fire when filling in or at fuel storage During adding the fuel overflowing should be preven ted After completion of filling oil should firmly retighten the tap of fuel tank When the diesel includes water the diesel generator is fit with fuel water separator to remove the water Only screw down the tap of the separator with left direction to drain off the wate fromt he fuel filter them retight the screw Remember to clese the fuel valve before drain the water from the fuel filter 3 2 2 Filing the lube oil The qualified lube oil should meet following condition ACEA B2 E2 or higher grade specification API CD CE CF 4 CG 4 or higher grade specification If adopting inferior lube oil should change the lube oil after every 150 hour operation It is very important to select the applicable engine oil for keep up the performance and life of the generating set If inferior engine oil is used or if your engine oil is not replaced periodically the risk of piston seizure piston ring sticking and accelerat2. Yon must know how to absolutely stop your group before using it Never allow someone to use the generator without having read the manual Always wear a safety shoes and keep you always ready to clean rags Keep children and pets away 2 COMPONENTS 1 Frame 2 Fuel level meter 3 Fuel cap 4 Air filter cover 5 Control panle 6 Fuel filter 7 Fuel valve 8 Speed gobernor 9 Oil Dipstick 10 Battery 11 Muffler 12 Wheels 1 Frame 2 Fuel level meter 3 Fuel cap amp 4 Air filter cover 5 Control panle 6 Fuel filter 7 Fuel valve 8 Speed gobernor 9 Oil Dipstick 10 Battery 11 Muffler 12 Wheels f 13 Oil filter 1 Plate 2 Main breaker 3 Controller fuse 2A 4 Contactor Key 5 Controller 6 16A circuit breaker 7 16A single phase socket 8 ATS connector 9 socket 10 12V connector 11 12V fuse 12 Earth connection 3 CHECR BEFORE USE 3 1 Notes for diesel generator set operation 3 1 2 Before operating diesel generator please read the manual Espe cially follovving points should be paid attention to for preventing the accident happened Preventing the fire The engine fuel is light diesel It is forbidden to adopt gasoline and kerosene etc When the oil overflows please use clean cloth to remove the oil It is not permitted to have diesel generator near to gasoline kerosene match and inflammable material because the temperature around the muffler is very high when the engine is operate
3. After installing the element fit the cover of air cleaner and retighten the clipper firmly 3 2 4 Checking the alternator Turn off main switch for unloading like lamp and motor etc Before starting the generator must turn off main switch If not in this position it is very dangerous for the generator to be started with the load so can damage the AVR and the alternator The alternator should be grounded correctly to prevent the shock by electricity ATTENTION The fuel and lube oil have been removed prior to delivery When filling in the fuel should check whether there is the air in the piping before starting If existing should drain off the air by unscrewing on fuel pump till no air bubbling comes out from the diesel then retighten the screw again new models are equiped with a air purge valve to take out the air of the fuel injector Do not open the valve when the generator works normally Just open to purge the air Air purgue valve B 3 CHECK BEFORE USE 3 2 5 Battery The battery The baterlf the accumulator is of liquid added type sis maintenance free During the operation the generator can automatically charge the battery If the generator is used for stand by application the charge of the battery could drop down We recommend to make at least 2 start up of the generator per week with at least 30min running in order to keep the battery recharge If longer time not starting the generator the batt
4. to the ON position and them the START generator is ready to receive load AE 9 Do not start more than two machines in the same time Only start c them one by one Do not use floodlights with other machines meanwhile Please refer to table bellow Home electric appliance Machine with rectifier typel Machine with capacitance incandescent lamp motor starting type Projector electric cooker Drilling machine grinding Water pump air compressor T V bulb microwave machine 8000 W 4000 W 1000 W 1000 W 5000 W 1500 W 10 4 START THE GENERATOR 4 5 DC applications DC terminal output is 12V 8 3A Red terminal refer to the positive poles of battery The rated voltage is 12V and charge 12V battery 1 When connecting automatic type accumulator must disconnect the wire from the cathode of the accumulator when charging 2 Starting diesel generator 3 Connect charging wire between accumulator terminal and gene rator anode DC connection Pay attention to the anode and catho de Otherwise it will make the generator and accumulator be damaged Do not let two terminals contact with each other which will make the circuit short When charging big capacity accumulator the charging current should be less than 8A Otherwise the fuse will burn 4 During charging the accumulator will make inflammable gas So place away spark flame and cigarette To avoid spark near the accumulator connect first the charging wires with t
5. EN DIESEL POWER GENERATORS DHY12000SE 3 DHY15000SE 3 USER MANUAL REVIEW MANUAL CAREFULLY TO AVOID PERSONAL INJURY MADE UNDER LICENSE OF HYUNDAI CORP SEOUL KOREA 10 SAFETY INFORMATION COMPONENTS CHECK BEFORE USE START OF THE ENGINE STOP OF THE ENGINE MAINTENANCE PROBLEM SOLUTIONS SPECIFICATIONS GUARANTEE NOTES 10 16 16 1 SAFETY INFORMATION In order to ensure a safety use of the generator please follow the next safety instructions 1 Check the outside of the generator in order to detect any appa rent trouble 2 The use or good quality oil and diesel is a must 3 Storage should be in a dry place Frost damage permanentiy your group Drain your machine completely before storing in a dry hot place 4 Check and clean filters regularly Be Make sure all subset of the machine are right 6 Exhaust fumes contain carbon monoxide a very dangerous gas colorless and odorless never use the generator in premi ses or areas closed Make sure the group is installed in a location with adequate ventilation or equipped with a smoke extractor T The exhaust temperature rises during the use of the group and stil burning even after shutdown Take care never to touch or move it to store before being on it is cool enough 8 Repair your generator shall be made by a qualified person and trained for this purpose 9 Do not smoke do not flame or spark when operating or fil
6. alarming of control panel 4 frequency too low too high 5 over current If the problem is not solved please contact your dealer 18 Generator Set I are li alt Log data Alternator L ETE Product Size mm Packaging Size mm Package A y i HYUNDAI agag la 6 DIESEL GENERATING SET GROUPE ELECTROGENE DIESEL O DIESEL STROMERZEUGER E GRUPO ELECTROGENO DIESEL GRUPPI ELETTROGENI DIESEL TYPE Leon o LEDO o FREQUENCY VOLTAGE Hz VO MW I VO NWPN LxWxH No KG GWPB KG nn X Length Width Height Length Width height Material DHY12000SE 1040 660 740 1140 730 790 Veneer Box DHY12000SE 3 1040 660 740 1140 730 790 Veneer Box DHY15000SE 1040 660 740 1140 730 790 Veneer Box DHY15000SE 3 1040 660 740 1140 730 790 Veneer Box Generator Model DHY 12000SE DHY12000SE 3 DHY15000SE DHY15000SE 3 Frequency Hz 50 50 50 50 Rated Power 8 7 KW 10 9 KVA 10 4 kW 13 0 KVA Max Power 9 2 KW 11 9 KVA 11 2 KW 14 0 KVA Voltage V 230 400 230 400 Current A 40 16 6 48 20 2 Sockets IGAR TX 32A 1 1x16083 8116411 1 TX 164 8 1321 1GA3 amp 160 1 1 Display LED5 LED5 LED5 LED5 Fuel Tank Capacity L 21 21 21 21 Running Time under 50 Load hr 18 18 17 5 IS Noise Level
7. behind 7 Meters 50 Load dBA 76 16 i n DC Output V A 2 12 8 3 12 83 RS VAS Battery Ah 36 36 36 36 Engine Type Diesel Diesel Diesel Diesel Engine D840E D840E D870E D870E Power Output HP 22 22 25 25 Start Method Elec star Elec star Elec star Electrical start Displacement ml 036 836 8 0 8 0 Oil Capacity L Vt 1 1 7 ie Alternator A9 1S A9 38 A12 5 18 A12 5 38 Rated Power kVA 9 11 125 14 Power Factor Coso 1 0 8 1 0 8 Voltage Regulation AVR AVR AVR AVR N W kg 245 245 245 245 G W kg 280 280 280 280 Loading capacity 20 40 40HQ 30 64 94 30 64 94 30 64 94 30 64 94 1 Single phase socket thermal protected 2 100W max output 10A fuse protection 19 DHY diesel generator set S Soundproof E electric start 3 three phase Specifications are subject to continuous product delevopment This generators are guaranteed for any failure or defect of fabrica tion for a period of 1 year or 1000 hours Non respect of the instructions in this user manual vvill avoid the guarantee 20 21 MADE UNDER LICENSE OF HYUNDAI CORP SEOUL ROREA
8. d For the sake of better ventilation during the generator operation the distance between diesel generator and the building should be more than 1 5 meters The diesel generator should be operated on plain ground Otherwise the oil will overflow from diesel generator Preventing the suction of exhaust gas For avoiding exhaust gas sucked by the person the diesel genera tor will be not allowed to work under condition of worse ventilation because exhaust gas emitted from the engine includes harmful CO 3 1 3 Preventing the damage by high temperature parts When diesel engine is working it is not allowed to touch high temperature parts such as muffler and its shell etc 3 1 4 Preventing the electric shock or short circuit For avoiding the shock by electricity or short circuit it is forbidden to touch with hand the alternator when working Do not operate the generator in raining or foggy For preventing the shock by electricity the grounding should be made with adoption of the wire which of one end is connected with the grounding terminal of the generator and another end is connected with the device outside The grounding terminal of the generator is on control panel 3 1 5 Other safety points It is very important to know how to stop the generator and the functions of all switches The untrained person is not permitted to operate the generator The operator should wear safe clothes and shoes during working fuel filter
9. ed wear of the cylinder liner bearing and other moving components increases significantly So the generating set life will be shortened We recommend CC CD oil classified by API Choose the applica ble viscosity oil according to the local ambient temperature Heplacement of the oil First replace after 20 hours Second to forth replace every 100hours Them every 200 hours Put the generator on plain ground then fill in lube oil through the opening of oil dipstick When checking oil level only place the dipstick into the hole When starting the generator each time should check oil level If not being enough should add the lube oil to the stipulated level Draining off lube oil can be immediately done after engine stopped because it is difficult to drain off the oil thoroughly when the engine is in cold state 1 Prime lube oil filter 2 Speed gobernor bolt 3 Speed gobernor 4 Oil dipstick 5 Manual speed stop 1 oil filter 2 Oil drain bolt 3 Drain groove 3 CHECK BEFORE USE 3 2 3 Check air cleaner D It is forbidden to clean the element with detergent 2 When output power drops or exhaust gas is black should change the element 3 It is not permitted to start the generator without air cleaner Otherwise it will cause the generator to be damage easily Air filter removal Unscrew the bolt and take out side plate Loosen the clipper to take out the cover of air cleaner for getting the element
10. ery can go out of charge so a exter nal charger should be used in order to complete the charge Please check regularly the charge of the battery should be over 12V in order to keep the battery in good conditions 3 2 6 Operation in trial For new engine it is necessary to have 20 hour running in opera tion initially A Avoiding over load During the trial operation should prevent over load B Changing lube oil at fixed period Change it after initial 20 hours operation sh e LI STARTER SW OFF ON a START OFF ON b START OFF ON c START THE GENERATOR 4 1 Preparation before starting 1 Turn fuel switch to ON position 2 Put speed handler of the engine at RUN position 3 Place circuit breakers in OFF position so no power is given by the generator 4 2 Starting 1 Insert the key to OFF position 2 Be sure the speed gobernoris set to RUN position 3 Turn the key to START position clockwise no longer than 5 seconds 4 After starting successfully remove the hand from the key to make the key be ON position automatically 5 If failed to start please wait 15 seconds for next starting If starting motor works too long the voltage of the accumulator will drop to cause the motor to be blocked During the operation let the key be in ON position 6 If the control panel is intelligent type also please refer to its manual 7 For remote con
11. he accumula tor before charging and disconnect from the generator after breaking down 5 Charge the accumulator under the place with better ventilation Before charging open the accumulator cover If electrolytic temperature is over 45 degrees Celsius should not recharge 4 6 Instruction for control panel function Three numeral code VOLT indicates the alternating voltage value virtual value unit V Three numeral code POWER shows the power value unit KW Three numeral code multifunctional related with 4 Trica DIESEL GENERATOR CONTROLLER DS O Ten bar codes show as following 11 4 START THE GENERATOR Frequency Hz Current A Battery voltage V Run time H Engine temp degrees Celsius Disuse MH Oo oO KR Q I Software release 8 Auto protection 9 Diesel valve on indicator 10 Starter indicator Six LED lamps show as following 1 Green lamp disuse 2 Green lamp indicate fan starting the fan will start when inner temperature is higher than set value 3 Red lamp Warning and indicate protecting for over temperature when the inner temperature is higher than 980 the red lamp will turn on the generator will stop if the temperature is continuously excess for 5 seconds meanwhile the red lamp twinkles 4 Red lamp lower diesel level warning when the diesel fuel level is low the red lamp will turn on the generator will stop if the le
12. he limits 10 the voltage digital code will twinkle if it continuously low for 7 seconds or continuously high for 3 seconds the auto protection will begin to take effect meanwhile the voltage digital code will continue twinkling and will show the value before protection If the auto protection setting is ineffective the voltage digital code will twinkle and the generator will not stop 2 Frequency protection 50Hz 47 55 60Hz 57 65 If the value exceed the limits the frequency digital code will twinkle if it continuously low for 7 seconds or continuously high for 3 seconds the auto protection will begin to take effect meanwhile the frequency digital code will continue twinkling and will show the value before protection If the auto protection setting is ineffective the frequency digital code will twinkle and the generator will not stop 1 Stop automatically The system will stop automatically when it meets auto protection condition The fuel oil way will cut off when the generator stops 2 Stop manually Under any condition the generator will stop when the key is turned to OFF position from ON position 14 5 STOP THE GENERATOR 5 1 Stop the generator 1 Before stopping the generator stop any machine connected 2 Move the thermal of 30mA leakage breaker to the lower position so the generator is not giving power 3 Let the generator run for at least 3 min without load in orther to cool it down 4 St
13. ing the key will show as 2 Current A 3 Battery voltage V 4 Run time H 5 Temp degrees Celsius 6 Disuse 7 Software release If lamp 8 is on auto protection is effective otherwise auto protection is ineffective If lamp 9 is on diesel valve is power up If lamp 105 is off the start motor is not power up Start of the Generator Under this mode the generator will stop when engine oil level is low or diesel level continuously low for 20 minutes or the tempe rature continuously excess for 5 seconds meanwhile the system is controlled automatically Turn the key to START position from ON position the genera tor starts meanwhile the diesel oil valve indicator and the starter indicator are both on while engine oil level indicator is off Loose the key after start at this time the diesel oil valve indicator is on the starter indicator is off the present value of voltage frequency and power are all shown Press By or Qy ordinally the other parameters are shown when pressing E it will go back to show frequency value 13 4 START THE GENERATOR 4 7 Autoprotection The protection that related with voltage frequency and overloading except engine oil temperature and diesel oil level are effective under auto mode If lamp 8 in the ten bar codes is on the auto protection is effecti ve otherwise it is ineffective 1 Voltage protection If the value is higher or lower than t
14. licance 19 Do not exceed the expecific current limit of any socket 20 Do not connect directly the generating set to a household circuit 18 No guarantee will be covered in case of non compliance of start up procedures and safety precautions 1 SAFETY INFORMATION Any use of the generator without reading this manual could cause hard damage to the machine o can hurt yourself seriously Pay special attenction to the next Do not use the generator in a non ventilated area o Do not use the generators in wet conditions Do not start the generator when device plug e Keep at least 1 meters from flammable objects Do not refill the fuel tank with the generator running Do not smoke when fuel refill e Do not overfill the fuel SAFETY GUARDS 1 Do not use Rerosene or other fuel only use diesel fuel Clean all the excess of fuel vvhen refill 2 Any flammable or explosive product shall be kept away from the generator due to the high temperature of the engine 3 Install your group on a flat horizontal surface to avoid spilla ge of gasoline 4 Inhalation of exhaust gas The exhaust gases contain poisonous carbon monoxide Never use the group in a poorly ventilated area 5 Never touch the exhaust when the generator is running or after starting 6 Short circuits Do not touch your group with wet hands The generator is not waterproof so it should not be exposed to water or snow 7 Other safety points
15. ling the tank store the generator near flammable materials 10 Store the group in a well ventilated area 11 Never transport or store your generator in a horizontal or dos of fuel leak and or oil or will permanently damage your machine 12 Never stop the generator when is load applied be sure to disconnect any apparatus from the generating set prior start of prior stop 13 Do not allow children to operate the engine Keep children and pets away from the area of operation 14 The engine and exhaust become very hot during operation Keep the generating set at least 1 5 meter away from buildings and other equipment during operation Keep flammable mate rials away and do not place anything on the engine while it is running 15 Use only diesel fuel 16 To avoid electric shocks or short circuit do not touch the gene rating set when your hands are wet This generating set Is not water proof so it should not be used in a place exposed to rain snow or water spray Use of the generating set in a wet place can cause short circuits and electric shock during operation 17 The generating set must be grounded to prevent electrical shocks from from faulty appliances Please connea lenght of heavy wires between the generating set ground terminal and a external ground source 18 Most applicance motors requiere more than their rated waltage for star up so follow recommendations of your dealer to choose the right power for your app
16. op the generator Electric start Turn the key to the off position Remote control Push the lock open key on the remote controller 6 MAINTENANCE 6 1 Maintenance at fixed period For the generator to work in conditions maintenance at fixed period is very important The diesel generator is consisted of diesel engine alternator control panel frame etc Before maintaining the generator stop the engine You should perform the maintenance in a well ventilated area After stopping the generator clean it immediately to prevent the corrosion and to remove the sediment ITEM everyda at 20h eve eve eve eve ear o mew een at 200 1008 or 1000h Check the fuel Clean fuel tan Check oil leakage Check each fastening Change lube oil Clean the element of air cleaner Clean fuel filter Check fuel pump Check the injector Check fuel pipe Adjust intake exhaust valve clearance Grind intake exhaust valve Change piston fi Check batte voltage ry EVERY MONTH 6 MAINTENANCE 6 2 Change lube oil TIME INTERVAL 20 hours for first time and 100 hours for next three times and 200 hours for normal operation Loosen oil drained plug located at the bottom of cylinder block when the engine is at hot state After removing used lube oil screw in the plug and add the stipulated oil Please refer to point 3 2 2 for detailed information 6 3 Change the element of air cleaner TIME INTERVAL every 500 ho
17. over and brush rock arm etc with a few rust proofed oil or lube oil without water 7 Wrap air cleaner and muffler with wet proofed paper to prevent the dust and moisture going in 8 Remove the dust and the oily on the frame and control panel 9 Take out the key 10 Disconnect battery connector from the battery 11 The generator should be stored at a place with better ventila tion clean dry and no corrosive material nearby 17 7 PROBLEM SOLUTIONS Causes Remedies Insufficient fuel Fill in the fuel Fuel switch not at DPEN position paride da a LOE Air in fuel circuit Purge air in fuel circuit No start No spray on injector or a little quantity Repair and adjust the injector of the engine Speed control rod not at RUN position Set control rod to RUN position The level between upper mark H Check lube oil lever andlowermark Dirty on the nozzle Clean the nozzle No electricity in battery Charge or change the battery No output Not turn on the switch Turn to CLOSE position of generator g Worse contact of the socket Adjust the socket Not reach rated speed of the engine According the stipulation Voltage too low Not reach rated speed of the engine Set speed control rod to operation position mE Check AVR Adjust the resistance clockwise Automatic stop after 1 lack of the fuel a certain 2 lack of lube oil time of operation Repair according to relative 3 voltage too low too high
18. trol start be sure there is no load before starting the generator 4 3 Difficulties on start up When it is difficult to start the engine in cold temperature the engine need to be equipped with glow plug Please require specially when buy engine It is very important to retighten oil dipstick firmly before starting Otherwise the engine parts will be worn out by rain dust and other impurities NOTE Do not adjust fuel quantity controller or speed limiter gobernor has been adjusted before delivery Otherwise the performance of the engine will be affected 4 START THE GENERATOR 4 4 Operation of the generator 1 Start the engine 2 Preheat the engine for three minutes without load Do not adjust fuel quantity controller or speed limiter gobernor has been adjusted before delivery Otherwise the performance of the engine will be affected 3 Read values of voltage and frequency in the display and wait to add load until this values are stable and according to the specifi cations of the product 4 Check whether there is abnormal sound or strong vibration STARTER SW SER Sn 5 Check whether the engine works out of order 6 Check the color of exhaust gas black or too white If any of them a mentioned before occurs you should stop the generator and then START contact with local dealer OFF ON 7 When voltage indicating on control panel reaches 10 of rated b limit can add the load 8 Place the circuit breaker up
19. urs please change the element often in dusty enviro ments Also is recommend to perfom a cleaning everytime the oil is change Please refer to point 3 2 3 for detailed information NOTE Do not clean the filter element with detergent 6 4 Change of fuel filter TIME INTERVAL every 500 hours replace for areas with poor quality of diesel the cleaning and changing of the oil filter should be made often After changing the fuel filter the the air should be purgue please refer to point 3 2 4 for details about purgue 1 Close fuel valve of the fuel tank 2 Remove the fuel filter 3 Place the new fuel filter 4 purgue the air if needed as explained in point 3 2 4 6 5 Long term storage When the generator will not operate for more than three months it should be stored 1 Drain off the fuel and lube oil 2 Remove the dust and the oily 16 6 MAINTENANCE 3 Clean the crankcase and gear chamber with diesel and kerose ne Then drain off them 4 Inject rust proofed oil or lube oil without water heat the lube oil to about 120 degrees Celsius till no foam exists into crankcase at stipulated level Then run the engine for three minutes to splash the oil to the surface of all moving parts Last drain off the oil after engine stopped 5 Inject rust proofed oil or lube oil without water into intake mani fold and then rotate the engine rapidly Last make intake exhaust valve be at close state 6 Dismantle cylinder head c
20. vel is continuously low for 20 minutes meanwhile the red lamp twinkles 5 Green lamp charging indicator to detect the charging and AC output of the vvinding if the charging and AC output are normal the lamp twinkles 6 Red lamp engine oil pressure warning the generator will stop automatically when the engine oil pressure is low meanwhile the red lamp twinkles Press button to navegater thru the functions Indication for engine oil pressure the lamp will be on when turn key on ON position for 10S and before the engine start show signal wire for the engine oil pressure is reliable If the lamp is not on when turn the key indicate that the failure connection for signal wire for engine oil pressure 12 4 START THE GENERATOR Turn key from OFF to ON when engine is stopped at this moment the voltage the current the frequency and the power values are all showing the set parameters and then will show after 2 seconds LOW OIL indicator lamp shows according to detection result the lamp is on when the switch of engine oil level is closed the switch should be closed when the generator is not working If the lamp is not on before running indicates there is something wrong with the switch of engine oil level or wiring Ten bar codes 1 lamp is on shows the frequency value the one on the top of the ten bar codes press button 3 in order the following value will shown on if continue press
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