Hyundai DHY12000SEV2 User manual

DIESEL GENERATOR
Model DHY12000SEV2
User Manual

Page 2
CONTENTS
Section Description
Page No/No’s
1. SAFETY
3 - 7
2. MACHINE LAYOUT
7 - 10
3. PREPARATION for STARTING
11 - 14
4. OPERATING THE GENERATOR
15 - 16
5. LOAD
16 - 17
6. STOPPING THE MACHINE
17 - 18
7. PERIODIC MAINTENANCE
18 - 21
8. LONG TERM STORAGE
22
9. TROUBLE SHOOTING
23
10. SPECIFICATIONS
24
11. SERVICE RECORD SHEET
25
12. GENPOWER CONTACT DETAILS
26
13. DECLARATIONS OF CONFORMITY
27

Page 3
1. SAFETY.
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.
Warning Signs and Symbols
Personal Protective clothing (PPE)

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1.3. Carbon Monoxide
1.3.1. Carbon monoxide is a colourless and odourless gas 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 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.
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 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.

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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. 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.

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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 electrolyte 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. To prevent fire.
1.5.1.1. Never add fuel to the fuel tank whilst the engine is running. Wipe away any
spilt fuel or oil with a clean cloth before operating. Keep explosives and any other
flammable products away from the machine at all times.
1.5.1.2. To prevent fire and to provide adequate ventilation, keep the generator at
least one metre away from buildings and other equipment during operation.
1.5.1.3. Operate the generator on level ground. - Do not place the generator indoors
whilst the engine is still hot.
1.5.2. To prevent inhaling exhaust fumes.
1.5.2.1. Exhaust gas contains poisonous carbon monoxide which is harmful to health
and can kill.
1.5.2.2. For this reason, never use the generator in a closed area or areas with poor
ventilation.
1.5.3. To prevent burns.
1.5.3.1. The muffler and the engine body becomes very hot whilst the engine is
running or just after running.
1.5.3.2. To prevent any burns, do not touch these parts during these times.
1.5.4. Electric Shocks, Short Circuits.
1.5.4.1. To avoid electric shocks or short circuits, do not touch the generator if your
hands are wet.
1.5.4.2. This generator is not waterproof and should not be used in an area which is
exposed to rain, snow or water sprays.

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1.5.4.3. The use of this generator in a wet place can cause short circuits and electric
shocks during operation.
1.5.4.4. The generator should be grounded to prevent electric shocks from faulty
appliances.
1.5.4.5. Connect a length of heavy cable between the generator's ground terminal
and an external ground source.
1.5.4.6. Do not connect tools or other appliances to the generator before it has been
started.
1.5.4.7. If equipment is connected starting the generator may cause sudden
movements of the equipment, resulting in accidents or injuries. It may also
damage the alternator.
DO NOT Connect the generator to Mains AC sockets in your building
– commonly known as ‘back feeding’ it is extremely dangerous and
illegal.
Most electric motors require up to 3 times the rated wattage to
start.
Do not exceed the specified current limit of any socket.

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2. MACHINE LAYOUT
2.1. Main Unit.
2.2. Inside Main Unit.

Page 9
2.3. Main Control Panel.
2.4. Control Module.
2.4.1. The Control Module only becomes active when the Module switch on the Control
panel is turned ON.
2.4.2. It can (where present) display the following faults;
2.4.2.1. Low Oil pressure,
2.4.2.2. High Temperature,
2.4.2.3. Over-Speed,
2.4.2.4. Engine Fault,
2.4.2.5. High/Low Volts and
2.4.2.6. Emergency STOP button activated.

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2.5. Control Module Functions.
2.5.1. The Control Module only becomes active when the Module switch on the Control
panel is turned ON.
2.5.2. After each successive press of the MENU button the Module will display the
following information;
2.5.2.1. Volts,
2.5.2.2. Frequency,
2.5.2.3. Hours RUN and
2.5.2.4. DC Battery Voltage.

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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
enters 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.
Always check the engine oil level with the generator on a flat,
level surface before starting or refilling the machine.
If an insufficient amount of engine oil is used, damage to the
engine may result.
Do not overfill the engine with oil.
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.
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
3.2. 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 –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.

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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 dipstick 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.

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3.3. Fill with coolant and antifreeze to the level marked.
3.4. 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.
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.
3.5.1.1. Warm up the engine 5 minutes after the initial starting, before applying load.
3.5.1.2. Avoid applying loads above 3kw during the first 20 hours of operation.
3.5.1.3. It is important to replace the engine oil on time.
3.5.1.4. Drain the engine oil whilst the engine is warm.
3.5.1.5. Ensure that old engine oil is drained out completely.

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3.6. Battery.
Do not connect tools or any other appliances to the generator before
starting.
Explosive gases are emitted when the battery is charging.
Only charge in a well-ventilated area, away from sparks and naked
flames.
Before charging, if possible, remove the cap from each cell of the
battery and ensure the electrolyte level is correct.(Does not apply to
sealed batteries).
3.6.1. Battery.
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 the control module check that the battery voltage is between 12.5v
and 13.6v.
3.6.1.3. The battery will be re-charged whilst the engine is running.
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 is a 12 volt 36Ah sealed lead acid battery and requires no
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.

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4. OPERATING THE GENERATOR
This generator should be grounded to Earth using a Ground earth
spike –tested to the current Electrical Regulations
If the engine has been running, the exhaust will become very hot. Be
careful not to touch the muffler until it has had time to fully cool
down.
Never refuel the fuel tank whilst the engine is still running.
This generator features a low oil pressure warning system. This is
activated by low oil pressure or engine oil shortage. In these cases
the engine will stop automatically. The machine will not restart
without refilling the engine oil. Check the oil level and refill.
DO NOT RELY ON THIS. Check oil daily.
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.
The fuel system is gravity fed to the fuel filter and pump.
4.1. Starting.
4.1.1. Make sure that the machine has,
fuel, water and oil
4.1.2. Make sure the emergency STOP
switch is out (turn anti-clockwise).
4.1.3. Turn the Module Switch to ON,
the display and the two gauges will
light up.
4.1.4. Press the green RUN button, the
machine will begin to crank and will start.
4.1.5. If the fuel has been changed or run out. The starting method will be to press the RUN
button and when machine begins to crank press the red STOP button, repeat this three
times. Then press green RUN button and let machine start as normal.
4.1.6. Run machine for five minutes before applying load
4.1.7. Insert the plug into the socket you are about to use.
4.1.8. Turn the main AC switch to the 'ON' position and turn the electrical appliance ‘ON’.
4.1.9. Do not overload the generator. This maximum output is 10kw, with maximum
continuous rating of 9kw. It is recommended that for long life, the load should be
between 40% and 80% of the maximum rating.
4.1.10. The generator is fitted with an overload breaker. This will overload (trip/break) when
the load on the generator reaches maximum. Avoid overloading the generator.
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.

Page 16
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 issues, stop the engine and locate the fault.
Please contact Genpower for assistance if required.
5. LOAD
Start appliances one-by-one. Do not start 2 or more appliances
simultaneously- start them one by one.
Induction loads, such as appliances with electric motors, especially air
compressors and pressure washers take up to 4 times the rated wattage
to start their motors. For example a 3hp (2200w/ 2.2kw) air compressor
can take up to 8800w/8.8kw to start it!
Do not use floodlights together with other appliances
5.1. 230 Volt AC use.
5.1.1. With engine running, switch ON the main breaker switch;
5.1.1.1. Check the Voltage reading when in ‘Voltage Mode’ (see 2.5. Control Module
Functions). It should read 230v ± 5%.
5.1.2. Check the Frequency reading when in ‘Frequency Mode’ (see 2.5. Control Module
Functions). It should read 50Hz.
5.1.3. Connect the equipment to the generator in correct order.
5.1.4. Connecting the loads with the largest motor first, then the smaller items.

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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 50% to 75% of rated
output.
5.1.7. Wait a few minutes before resuming operation.
5.1.8. 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
5.2. 12v DC use.
Connect the positive and negative charging lead clips to the correct
poles of the battery.
If you try to charge a large capacity battery, which is at a low voltage,
excessive current flow may occur. This may result in the fuse for the
12v DC blowing.
Do not use 12V DC and 230V AC at the same time.
5.2.1. DC terminals are only for charging 12V batteries.
5.2.2. Set the main AC breaker switch to the 'OFF' position whilst charging.
5.2.3. If you undertake regular battery charging, it is advisable to use a 230v battery
charger run from the 230v circuit, for a more efficient charge.
6. STOPPING MACHINE
Do not stop the engine suddenly or whilst under load.
This can damage the AVR and cause damage to the alternator
through overheating.

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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. Press the STOP button.
6.5. Once machine has stopped turn OFF
the Module Switch.
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.
7.1. Maintenance chart.
7.1.1. All work/s should be carried out by a suitable qualified person.
7.1.1.1. If you need technical advice please contact Genpower.
Item
Daily
First
Month
or 20
hours
Six
Months
or 250
hours
Six
Months
or 500
hours
Every
Year or
1000
hours
Check and refill with diesel
●
Change engine oil
●First
Time
●
Check and refill engine oil
●
Check for oil leakage
●
Check and tighten fastening parts
●
●
Replace engine oil filter
●
Replace air cleaner element –Service more
frequently in dusty areas
●
Replace fuel filter
●
Check fuel pipes
●
Replace
as
required
Adjust clearance of intake/exhaust valves
●
Grind intake/exhaust valves
●
Check physical condition of battery
●
Check battery voltage
●
Check carbon brushes and slip rings
●

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7.2. Replacing engine oil.
After engine has been run prior to changing 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. Loosen the Oil Filler Cap.
7.2.2. Remove the Oil Drain Plug and drain the old oil while the engine is still warm.
7.2.3. Fit new copper washer as required.
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.
7.2.5. Clear up any spillages.
7.2.6. Tighten the Oil Filler Cap.

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7.3. Replacing oil filter.
7.3.1. Loosen the Oil Filler Cap.
7.3.2. Remove the Oil Drain Plug and drain the old oil while the engine is still warm.
7.3.3. After draining, re-tighten the drain plug.
7.3.4. Remove old filter and replace with new. Fit new copper washer as required.
7.3.5. Refill with the recommended oil API CH-4/CF/SJ/SL diesel engine oil or higher
grade.
7.4. Servicing the Air Filter.
Do not wash air filter –blow out any dust from housing
using a low pressure air-line.
Replace the air filter if the engine output decreases or
excessive exhaust smoke is noticed.
Never run the generator without the air filter, otherwise
rapid engine wear will result.
7.4.1. Open access door to right of control panel.
7.4.2. Air filter is mounted low and to the left
7.4.3. Undo the two clips and remove the air filter cover and
take out the air filter.
7.4.4. Clean the air filter.
7.4.5. Reverse this process to re-install filter.
7.5. Clean and Replace Fuel Filter.
•Never run the generator without the fuel filter.
7.5.1. Drain out the fuel from the fuel tank.
7.5.2. Replace filter.