Hyundai DHY6000SELR2 User manual

DIESEL GENERATOR
Model DHY6000SELR2
User Manual

CONTENTS
Section Description
Page No/No’s
1. SAFETY
3 –7
2. MACHINE LAYOUT
8 –9
3. PREPARATION for STARTING
10 –13
4. OPERATING THE GENERATOR
14 –15
5. LOAD
15 –16
6. STOPPING THE MACHINE
16
7. PERIODIC MAINTENANCE
16 –17
8. LONG TERM STORAGE
18
9. TROUBLE SHOOTING 19
10. SPECIFICATIONS
20
11. WIRING DIAGRAM
21
12. SERVICE RECORD SHEET
22
13. GENPOWER CONTACT DETAILS
23
14. DECLARATIONS OF CONFORMITY
24
Page 2

1.
1.1.2. The machine 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
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.
Warning Signs and Symbols
Personal Protective clothing (PPE)
Page 3
SAFETY.
1.1. The operator of the machine is 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.
Please note the following safety points
CORROSIVE

1.4. General fuel safety.
1.4.1. Fuel Safety additional information can be obtained from the Health and Safety
Executive (HSE) document SR16.
1.4.2. All fuels are Flammable.
1.4.3. Keep away from all ignition sources i.e. Heaters, Lamps, sparks created 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
1.3. Carbon Monoxide
1.3.1. Carbon monoxide is a colourless and odourless. Breathing in this gas 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 KEKd Use Petrol/Diesel powered
equipment in an enclosed area or a moving vehicle.
1.3.4. If you think you or someone around you has been affected by carbon
monoxide poisoning you must take the following action;
1.3.4.1. Get fresh air immediately.
1.3.4.2. If you have used indoors 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.

1.4.7. 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.
1.4.8.3. Hand protection.
1.4.8.4. Protective clothing.
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.
1.4.9.1. 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.
1.4.9.3. 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. That they 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.
Page 5

1.4.10.5. Never work on or near electricity with wet hands, wet clothing, or wet
gloves.
1.4.10.6. Batteries present a risk if they are damaged there maybe the
possible risk of leaking electrolyte. This electrolyte is an acid and can cause
serious injuries. Care should be taken when working on or near batteries.
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 the acid comesinto contact with a persons or 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 in 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 metre from buildings or other equipment, or the
machine 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 start again.
1.5.3. Starter Switch (SW)
1.5.3.1. The engine starter switch controls the ignition.
1.5.3.2. In the ‘OFF’ Position the ignition circuit is switched
off and the engine will not run
1.5.3.3. In the ‘ON’ position the engine is ready for starting
1.5.3.4. In the ‘START’ position (pushed against spring
tension) the starter motor is engaged and the machine
will start.
Page 6
1.4.10.6.1.6. Make sure the charging location is not near where hot working such as
welding grinding or drill is taking place.

1.5.4. AC Switch (Breaker)
1.5.4.1. The AC Switch (Breaker) will turn ‘OFF’ automatically
when the load connected exceeds the generator output.
1.5.4.2. If AC switch turns ‘OFF’ then before resetting remove all
of the load connected to the machine. Make sure you keep the
load required below the rated output of the machine.
1.5.4.3. Then turn on the equipment making sure not to overload
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.
Page 7

2. MACHINE LAYOUT
Page 8

1 Starter Switch 5 Breaker 9 DC Fuse
2 Oil Warning
Lamp 6 16 Amp –230 Volt AC Outlet 10
DC
Connection
Points
3 Voltmeter 7 32 Amp –230
Volt AC Outlet 11 ATS Connection
4 Hours Run 8 Ground/Earth
point
Page 9
Control panel

3. PREPARATION for STARTING
DO NOT refill tank while engine is running or HOT.
Do not smoke or allow flames or sparks in the area where the
engine is refuelled or where the fuel is stored.
Do not overfill the diesel tank and make sure the filler cap is
securely closed after refuelling.
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.
Wear suitable PPE, suggested but not limited too
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, make sure that no dust or water is
allowed to mix with the fuel, or enter the tank. 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.
3.1.1.6. Checking the engine oil level.
3.1.1.7. There is no gauge for oil level. It is the users responsibility to check the
engine oil level daily.
3.1.1.8. Always check the engine oil level with the generator on a flat, level
surface before starting or refilling the machine.
3.1.1.9. If an insufficient amount of engine oil is used, this may cause serious
damage to the engine.
3.1.1.10. Do not overfill the engine with oil.
3.1.1.11. This generator is equipped with a low pressure oil switch. This system will
stop the engine automatically when the oil pressure falls below the minimum
pressure required.
3.1.1.12. 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.
Wear suitable PPE, suggested but not limited too
Page 10
Wear suitable PPE, suggested but not limited too.

3.2. Check and refill the engine oil.
3.2.1. To ensure the generator maintains an
optimum performance and the longevity of
the life of the generator, it is important to use
the correct engine oil –SAE15W/40 (API CH-4/
CF/SJ/SL diesel engine oil or higher grade)
and change after the first 20 hours, then
every 100 hours.
3.2.2. If the correct engine oil is not used, or the
engine oil 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.
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
SAE15W/40, API CH-4/CF/SJ/SL diesel engine oil. Fill
to dipstick mark 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. If you suspect that the engine oil is contaminated in any way then it is
recommended you change the engine oil
3.3. Checking the air cleaner.
Do not wash air filter with detergent.
Replace the air filter if the engine output decreases or
excessive exhaust smoke is noticed.
Never run the generator without the air filter, this
practice will result in rapid excessive wear of the engine.
3.3.1. Lift the canopy to access the air filter
cover.
3.3.2. Once inside loosen the filter retaining nut
(anti-clockwise) and remove the air cleaner cover
and take out the element.
3.3.3. Clean the air filter or replace if necessary.
3.3.4. Reattach the air filter cover and screw on the nut.
Page 11

3.4. Fuel Filter Service.
3.4.1. Drain out the fuel from the fuel tank.
3.4.2. Move the clamps on the pipes away from the filter connections. Clamp the pipe
above the fuel filter.
3.4.3. Remove fuel filter and fit a replacement and re-position clamps on
filter.
3.5. Checking the Generator before start up.
Be sure to turn off the main breaker switch before starting. The
generator should be earthed to prevent electric shocks.
Turn off the main breaker switch and remove all loads.
Before starting the engine, be sure to switch OFF any appliances
connected to it.
Ensure that the breaker switch is OFF before switching between
115v/230v.
3.6. Running-in periods of Operation.
3.6.1. The first 20 hours are the running-in period of the engine. For this reason, it is
important to follow the following instructions during this period.
3.6.1.1. Warm up the engine 5 minutes after the initial starting, before applying load.
3.6.1.2. Avoid applying loads above 3kw during the first 20 hours of operation.
3.6.1.3. It is important to replace the engine oil as per the schedule recommended
by the manufacturer.
3.6.1.4. Replace the engine oil whilst the engine is warm.
3.6.1.5. Ensure that old engine oil is drained out completely.
Page 12

3.7. Battery.
Explosive gases are emitted when battery is charging. Only
charge in a well-ventilated area, away from sparks and naked
flames.
3.7.1. Battery.
3.7.1.1. 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.
3.7.1.2. Using a voltmeter - check the voltage is 12.3V+, if lower, the battery must be
charged.
3.7.1.3. 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.
3.7.1.4. 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.
3.7.1.5. Make sure that all battery acid spills are correctly cleaned up straight away.
3.7.1.6. The battery should be stored in a charged condition.
3.7.1.7. The battery is a 12 volt 36Ah sealed lead acid battery and requires no
maintenance other than;
3.7.1.7.1. Ensure battery terminals are;
3.7.1.7.2. Kept clean.
3.7.1.7.3. Each terminal is securely fixed and tight.
3.7.1.7.4. Covered to prevent short circuiting.
3.7.1.8. If the battery voltage is too low, it will require charging before use.
3.7.1.9. Keep the battery in a cool, dry place. It is important to clean the battery every
three months and charge every six months.
Page 13

4. OPERATING THE GENERATOR
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 sufficient fuel.
4.1.3. Set the engine speed lever is set to ‘RUN’. 4.1.4.
Turn the starting key clockwise to the 'START'
position.
4.1.5. Remove your hand from the key as soon as the
engine starts.
4.1.6. If the engine does not start after 10 seconds, wait
15 seconds before trying again. Excessive start
attempts will cause the battery to discharge.
4.1.7. If it does not start after 3 attempts, or runs
intermittently with excessive smoke check that the
fuel system is fully primed.
4.1.7.1. Priming - before starting to prime make sure that
there is sufficient fuel in tank and that you can
contain any fuel spilt.
4.1.7.1.1. Begin by releasing the fuel pipe clip on the diesel fuel line connected to
the injector pump. Remove the pipe and make sure you pinch the fuel line,
then slowly release until all air is released and fuel appears.
4.1.7.1.2. When fuel appears replace the fuel pipe onto the injector pump
and replace clip. Clear up any fuel spills before restarting.
4.1.7.1.3. The above may be necessary when new, or if the machine runs out of
fuel.
Page 14

4.1.8. Always leave the key in the ‘ON’ position whilst the engine is running.
4.1.9. Run machine for two minutes before applying load
4.1.10. Insert the plug into the socket you are about to use.
4.1.11. Turn the main AC switch to the 'ON' position and turn the electrical appliance ‘ON’.
If the engine has been running, the muffler will become very hot. Be
careful not to touch the muffler until it has had time to fully cool
down.
Never fill 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.
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.
If you notice any of the above, stop the engine and locate the
fault.
Please contact Genpower for assistance if required.
5. LOAD

Always start appliances one-by-one.
5.1. 230 Volt AC use.
5.1.1. With engine running switch ON the main breaker switch, with
the engine running check the Voltmeter is reading read 230v ±
5% (@50Hz).
5.1.2. Connect the equipment to the generator in the correct order.
5.1.3. Connecting the loads with the largest motor first, then the
smaller items.
5.1.4. If the generator is overloaded the main breaker will trip.
Page 15

5.1.5. To reset the breaker you must do the following;
5.1.5.1. Turn OFF and disconnect all loads.
5.1.5.2. Reset breaker, and add load onto the circuit to within 50% to 75% of rated
output.
5.1.6. 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.
Type
Wattage
Typical
appliance
Example
Starting
Rated
Appliance
Starting
Rated
Lighting
x 1
x 1
Incandescent
lamp or heating
appliance
Incandescent
lamp 1000
watts
100 vA
100 vA
Heating
Appliance
Fluorescent
Lamp
x 2
x 1 to x 1.5 Fluorescent
Lamp
Fluorescent Lamp
80 vA
40 to 60
vA
Motor
Driven
Equipment
x 3.5
x 1 to 2
Refrigerator,
Electric fan,
Compressor or
grinder
Refrigerator 150
watts
450 to 750
vA
150 to 30
vA
6. STOPPING MACHINE
Do not stop the engine suddenly or whilst under load.
This can damage the Automatic Voltage Regulator (AVR)and
cause damage to the alternator through overheating.
Do not stop the engine with the decompression lever.
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.
6.4. Turn the electric key start switch to the 'OFF'
position.
6.5. Or press down the stop lever.
7. PERIODIC MAINTENANCE
Ensure the engine is off before performing any service.
If the engine must be run, make sure that the area is well ventilated.
The exhaust contains poisonous carbon monoxide gas.
Page 16

7.1. Maintenance chart.
All work/s should be carried out by a competent person –if you need technical advice contact Genpower
Item
Daily
First
month
or 20
hours
Every
100
hours
Every
500
hours
Every year
or 1000
hours
Check and refill with diesel
Yes
Check and refill with engine oil
Yes
Check for oil leakage
Yes
Check and tighten fastening parts
Yes
Yes
Replace engine oil
Yes First
oil
change
Yes
Clean engine oil filter
Yes
Replace engine oil filter
Yes
Replace air filter
Yes
Replace fuel filter
Yes
Check Fuel injection pump
Yes
Check injector nozzle
Yes
Check fuel pipes
Yes
Adjust clearance of intake and exhaust valves (0.15mm for
both)
Yes –
First time
Yes
Grind intake/exhaust valves
Yes
Replace piston rings
Yes
Check physical condition of battery N.B. Check battery
voltage monthly
Yes
Check carbon brushes and slip rings
Yes
7.2. Replacing engine oil.
After engine has been running and prior to carrying out an oil change the oil
will be very hot.
Wear correct PPE minimum of gloves and overalls.
DO NOT allow any dust, dirt or any other debris enter oil or crankcase.
7.2.1. Raise machine off of the floor so that you can put a
receptacle to catch the old oil, Remove the oil filler
cap.
7.2.2. Remove the drain plug and drain the old oil while
the engine is still warm.
7.2.3. The plug is located on the bottom of the cylinder
block. The oil will drain into a small tray and then out
of the machine to the oil receptacle under
machine. 7.2.4. After draining, re-tighten the drain plug
and refill
with the recommended oil API CH-4/CF/SJ/SL diesel
engine oil or higher grade.
Page 17

8. LONG TERM STORAGE
After running the engine the oil will be very hot.
Wear correct PPE minimum of gloves and
overalls.
8.1. If storing the generator for long periods of time, make the following operations.
8.1.1. Operate the engine for 10 minutes.
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 18

9. TROUBLESHOOTING.
9.1. Troubleshooting - N.B. all corrective actions should be carried out by suitably qualified
person/s.
Problem
Possible fault/cause
Remedy
The Diesel engine will not
start
The governor lever is not at
START position
Set lever to START position
The start motor turns slowly
Check battery performance
and all connections
The battery is discharged
Charge or replace with a new
one
Check the engine oil level
The specified oil level should
be to the upper lever
Insufficient fuel
Refill with fuel
Fuel injection pump does not
deliver fuel or delivers
insufficient fuel
Remove the injector pump
and have it tested
The injector has severe carbon
build-up
Clean the injector
The generator is not
producing power
Main breaker switch has not
been turned ON
Turn the main breaker to the
ON position
The contact in the socket is
not good
Make sure plugs are fully
inserted into sockets
AVR is damaged
Replace AVR
The rated speed is too HIGH
or too LOW
Adjust engine speed to
produce 52 Hz with no load
Alternator brushes worn
Replace the brushes
Page 19

10. SPECIFICATIONS
Model
DHY6000SELR2
Generator
Frequency Hz
50 Hz
Continuous Output Power kW
5 kW
Max Power
5.5 kW
Voltage AC Volts
230VAC
Sockets
1 x 16A, 1 x 32A @230V
Fuel Tank capacity (Litres)
30
DC Output Volts - Amps
12V 8.3A
Battery
12 v 36Ah
Engine
Engine Type
Diesel
Engine
D400, Forced Air- cooled, OHV
Power Output HP
10 HP
Start method
Electric
Displacement cc
418 cc
Engine Speed rpm
3000 rpm
Lubrication Oil
15W/40 (API CH-4/CF/SJ/SL diesel engine oil
grade or higher)
Lubrication Oil Capacity (Litres)
1.75 Litres
Rated Power (kW)
5.2 kW
Power Factor cosᶲ
1
Voltage Regulation
Automatic Voltage Regulation - A.V.R.
Weight - Dimensions
Nett Weight Kg
160Kg
Dimensions (L x W x H) mm
930 x 570 x730
Page 20