Hyundai DHY6000LE User manual

DIESEL GENERATOR
SERVICE MANUAL
Licensed by Hyundai Corporation, Seoul, South Korea
OPEN TYPE: DHY6000LE / DHY6000LE-3
SOUNDPROOF TYPE: DHY6000SE / DHY6000SE-3

This manual contains information how to maintain and how to do troubleshooting.
Keep this owner’s manual handy, so you can refer to it at any time.
This service manual describes correct method of the maintaining this equipment. As a result of
this disregard of our rules caused by person casualty and equipment damaged, our company
does not assume any responsibility.
NOTICE:
Copyright reserved, and no part of this publication may be reproduced without our
Company’s written permission.
SAFETY MESSAGES
Your safety and the safety of others are very important. We have provided important safety
mes3ges in this manual and on the generator. Please read these messages carefully.
A safety message reminds you to potential hazards that could hurt you or others. Each safety
message is preceded by a safety alert symbol and one of three words: DANGER,
WARNING, or CAUTION. These mean:
You WILL be KILLED or SERIOUSLY HURT
if you don’t follow instructions.
You CAN be KILLED or SERIOUSLY HURT
if you don’t follow instructions.
You CAN be HURT if you don’t follow instructions.
Your generator or other property could be damaged
if you don’t follow instructions.
NOTICE
DANGER
WARNING
CAUTION
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POWER PRODUCTS

1 PREFACE 1
1-1 Generator Component Identification 1
1-2 Control Panel 3
1-3 Specifications of generator 4
1-4 Specifications of engine 6
1-5 Maintenance Standard 7
2 Periodic Maintenance 9
2.1 Service Intervals 9
2.2 Routine Maintenance Procedures 10
3. Engine Disassembly and Reassembly 13
3.1 Disassembly 13
3.2 Reassembly 19
3.3 Recoil Starter Assembly 25
4. Inspection and Service 28
4.1 Cylinder Head 28
4.2 Piston and Piston Pin 30
4.3 Connecting rod 32
4.4 Crankshaft, main bearing and flywheel 33
4.5 Camshaft 34
4.6 Timing Gear 34
4.7 Crankshaft Cover 35
4.8 Cylinder Sleeve and Block 36
4.9 Lubricating System 36
4.10 Fuel System 38
4.11 Governor 39
4.12 Adjustments 40
5. Troubleshooting 42
5.1 No fuel delivery to injection pump 42
5.2 No fuel flow from drain valve 42
5.3 Low compression 42
5.4 Hard starting (fuel delivery and compression normal) 42
5.5 No start or hard start (engine cranks) 42
5.6 Engine over speed 43
5.7 Unsteady engine speed 44
5.8 Unexpected shutdown 44
6 Generator 45
6.1 Removal/Installation 45
7 Circuit diagram 51
8 Appendix 53
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POWER PRODUCTS
CONTENTS

Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.
1. PREFACE
1-1 Generator Component Identification
Open Type: DHY6000LE, DHY6000LE-3
1
FUEL TANK
FUEL TANK CAP
CONTROL PANEL
UP COVER FRAME
DIESEL ENGINE
RECOIL STARTER
INJECTION PUMP
SPEED GOVERNOR
COCK OF OIL DRANING
OIL PUMP
BATTERY
BOTTOM FRAME
RUBBER ABSORBER
ALTERNATOR
PUSH WHEEL KIT
MUFFLER
START MOTOR
BATTERY CHARGER
OIL DIPSTICK
AIR CLEANER
POWER PRODUCTS

Soundproof Type: DHY6000SE, DHY6000SE-3
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POWER PRODUCTS
FUEL TANK CAP HOOK CONTROL PANEL
AC OUTPUT SOCKET
PUSH WHEELS
FRONT DOOR
FUEL LEVEL INDICATOR
MUFFLER
2

LED4 DISPLAY
LED4 DISPLAY
ELECTRIC START KEY
ELECTRIC START KEY
1-2 CONTROL PANEL
E-STOP BUTTON
LEAKAGE BREAKER
LEAKAGE BREAKER
PCB
PCB
12V DC TERMINALS
GROUND TERMINAL
GROUND TERMINAL
12V DC SOCKET
SOCKET
PRE-HEATER BUTTON
PRE-HEATER BUTTON
ATS SIGNAL SOCKET
ATS SIGNAL SOCKET
12V DC FUSE
12V DC FUSE
IP66 WATERPROOF
COVER
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POWER PRODUCTS
OPEN TYPE: DHY6000LE
SUNDPROOF TYPE: DHY6000SE
3

1-3 Specifications of generator
Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.
Hz
kVA
kW
kVA
V
A
L
Hours
dBA
Hp
cc
L
kVA
cosφ
kg
kg
mm
mm
unit / container
DHY6000LE
50 / 60
4.5 / 5.0
4.5 / 5.0
5.0 / 5.5
230 / 240
19.6 / 20.8
1- phase
Electric & Manual
14
5.2
79
12V/36Ah
D400E
10.0
Electric & Manual
418
1.65
5kVA 190L-138/D50(D60)
5
1
Blush type / AVR
140
147
DHY6000LE-3
50 / 60
5.6 / 6.3
4.5 / 5.0
6.2 / 6.9
230 / 240
8.1 / 8.6
3- phase
Electric & Manual
14
5.2
79
12V/36Ah
D400E
10.0
Electric & Manual
418
1.65
6.3kVA 190L-138/D50(D60)
6.3
0.8
Blush type / AVR
142
149
Electrical standard and options DHY6000LE DHY6000LE-3
1-phase (2×15A Australian sockets)
3-phase (1×15A Australian socket )
American;UK;European sockets;etc
Display LED4
Display LED3
Prosice overload protection
Common overload protection
DC output:12V / 8.3A
Earth connection
Pre-heater
ATS sensor
Remote control
ATS control box(50A)
Mechanical standard and options
Frame tube diameter 32mm
Basic color：Pantone black C
Alternator：Steel plate Q195
Alternator：Silicon steel plate DW800
Push wheel kit
●
×
○
●
○
●
○
●
●
○
○
○
○
●
●
●
○
○
×
●
○
●
○
●
○
●
●
○
○
○
○
●
●
●
○
○
Generator Model
Frequency
Rated power
Max. power
Voltage
Rated current
Phase
Start mode
Fuel tank capacity
Fuel consumption 50% load
Sound pressure level(7m 75% load)
Battery
Engine Model
Rated power
Start mode
Displacement
Oil capacity
Alternator Model
Rated power
Power factor
Voltage regulation
Dimension and Weight
Net weight
Gross weight
Product dimension (L×W×H)
Box dimension (L×W×H)
Capacity
720×480×600
740×500×640
99/20GP; 207/40GP; 220/40HQ
Option :
○
Standard feature :
●
No available :
×
4
POWER PRODUCTS
open type

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POWER PRODUCTS
Hz
kVA
kW
kVA
V
A
L
Hours
dBA
Hp
cc
L
kVA
cosφ
kg
kg
mm
mm
unit / container
DHY6000SE
50 / 60
4.5 / 5.0
4.5 / 5.0
5.0 / 5.5
230 / 240
19.6 / 20.8
1-phase
Electric
15
6
70
12V/36Ah
D400E
10.0
Electric
418
1.65
5kVA 190L-138/D50(D60)
5
1
Blush type / AVR
170
180
DHY6000SE-3
50 / 60
5.6 / 6.3
4.5 / 5.0
6.2 / 6.9
400 / 420
8.1 / 8.6
3-phase
Electric
15
6
70
12V/36Ah
D400E
10.0
Electric
418
1.65
6.3kVA 190L-138/D50(D60)
6.3
0.8
Blush type / AVR
172
182
Electrical standard and options DHY6000SE DHY6000SE-3
1-phase (2×16A European sockets)
3-phase (1×16A European socket )
American;UK;Australian sockets;etc
Display LED4
Display LED3
Prosice overload protection
Common overload protection
E-stop button
DC output:12V / 8.3A
Earth connection
Pre-heater
ATS sensor
Remote control
ATS control box(50A)
●
×
○
●
○
●
○
○
●
●
×
×
×
×
×
●
○
●
○
●
○
○
●
●
○
○
○
○
Mechanical standard and options
Basic color： Pantone black C
Alternator： Steel plate Q195
Alternator： Silicon steel plate DW800
Decompression handle
●
○
●
○
●
○
●
○
920×520×740
960×560×790
48/20GP; 96/40GP; 144/40HQ
Generator Model
Frequency
Rated power
Max. power
Voltage
Rated current
Phase
Start mode
Fuel tank capacity
Fuel consumption 50% load
Sound pressure level(7m 75% load)
Battery
Engine Model
Rated power
Start mode
Displacement
Oil capacity
Alternator Model
Rated power
Power factor
Voltage regulation
Dimension and Weight
Net weight
Gross weight
Product dimension (L×W×H)
Box dimension (L×W×H)
Capacity
Option :
○
Standard feature :
●
No available :
×
soundproof type
5

1-4 Specifications of engine
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6
POWER PRODUCTS
D400/E
Single cylinder, vertical, 4-stroke, air-cooled
86x72 (3.39x2.83)
0.418 (418)
19:1
3000 3600
5.9 (8.0) 6.6 (9.0)
6.6 (9.0) 7.3 (10.0)
5.5 (1.45)
≤2.15 (0.57)
1.65 (0.435)
Recoil starter / Elec. starter
crankshaft / camshaft
0#(summer), -10#(winter) diesel
CD grade or SAE10W-30 15W-40
Recoil start=48 (105.6);Elec. Start=53 (117)
417x470x494 (16.42x18.50x19.45)
Diesel Engine Model
Type
BoreXstroke [mm(in)]
Displacement [L(cc)]
Compression ratio
Rated speed (rpm)
Rated power [kW(Hp)]
Max. power [kW(Hp)]
Fuel tank capacity [L(US.gal)]
Fuel consumption [L(US.gal)/hr.
Lube oil capacity [L(US.gal)]
Starting Fashion
Output Shaft
Fuel trademark
Oil trademark
Net Weight [kG(lbs)]
Overall dimension L×W×H [mm(in)]
D: diesel engine 400:model code E: electric start
D400
D400
Air cooled diesel engine
Performance
Performance
Curves
Curves
Dimensions
Dimensions
PTO
PTO
Dimensions
Dimensions
Engine
Engine
Flagers
Flagers
PTO
PTO
Keyway shaft
Keyway shaft
Thread shaft
Thread shaft
Taper shaft
Taper shaft
Crankshaft
Crankshaft
PTO
PTO
Camshaft
Camshaft
PTO
PTO
417
2.8
2.6
2.4
2.2
2
28
26
24
22
20
Kmg Nm
PS kW
Output
7
6
5
4
3
2
10
9
8
7
6
5
4
3
2
Torque
Sd
6
4
2
0
Smoke Density
Exhaust Temperature
Specification Fuel Consumption
°C
600
500
400
300
200
220
210
200
190
180
170
300
280
260
240
220
g/kWh g/PSh
Engine Speed min
-1
1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000 3200 3400 3600 3800 4000
2.8
2.6
2.4
2.2
2
28
26
24
22
20
Kmg Nm
PS kW
Output
7
6
5
4
3
2
10
9
8
7
6
5
4
3
2
Torque
Sd
6
4
2
0
Smoke Density
Exhaust Temperature
Specification Fuel Consumption
°C
600
500
400
300
200
220
210
200
190
180
170
300
280
260
240
220
g/kWh g/PSh
Engine Speed min
-1
1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000 3200 3400 3600 3800 4000
7.3kW(10.0hp)

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1-5 Maintenance Standard
Parts Item Standard Service limit
Engine
Maximum Speed (No Load)
Cylinder Compression
3150~3180rpm
≥1.17Mpa(1400rpm)
--
--
Cylinder Sleeve I.D
Cylinder Head
Cover Warpage -- 0.10mm
Piston
Skirt O.D.
Piston-to-Cylinder Clearance
Piston Pin Bore I.D.
Piston Pin O.D
Piston Pin-to-Piston Pin Bore Clearance
0.015-0.05mm
18.0mm
0.002-0.014mm
0.12mm
17.954mm
0.06mm
Piston Rings
Ring Side Clearance：
Second
Ring Enc Gap:
Second
Ring Width
Second
0.015-0.045mm
--
0.2-0.4mm
0.15-0.35mm
1.5mm
2.5mm
0.15mm
--
1.0mm
1.0mm
1.37mm
2.37mm
Connecting
Rod
Small End I.D
Big End I.D
Big Oil Clearance
Big End Side Clearance
18.002mm
30.02mm
0.040-0.063mm
0.1-0.7mm
18.07mm
30.066mm
0.12mm
1.1mm
Crankshaft Crankshaft pin O.D 29.98mm 29.92mm
Valve
Valve Clearance IN
EX
Stem O.D IN
EX
Guide I.D
Stem Clearance IN
EX
Seat Width
Spring Free Length
0.15±0.02mm
0.20±0.02mm
5.48mm
5.44mm
5.50mm
0.02-0.044mm
0.06-0.087mm
0.8mm
34mm
--
--
5.318mm
5.275mm
5.572mm
0.1mm
0.12mm
2.0mm
32.5mm
7
Diesel Engine
Diesel
86.0mm
85.94mm
Ø23mm Ø23.05mm
85.80mm
86.185mm
+0.035
0
-.0002
-0.008
POWER PRODUCTS

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Camshaft
Cam Height IN
Cam Height EX
Journal O.D
27.7mm
27.75mm
13.984mm
27.45mm
27.50mm
13.916mm
Crankcase
Cover Camshaft Bracket I.D 14.0mm 14.048mm
Carburetor
Main Jet
Float Height
Pilot Screw Opening
#68
13.7±1.5mm
2-1/8 turns
--
--
--
Spark Plug Gap 0.7-0.8mm --
Spark Plug
Cap Resistance 5kΩ--
Ignition Coil
Resistance Primary Coil
Secondary Coil
Air gap
0.8-1.0Ω
5.9-7.1kΩ
0.4-0.6mm
--
--
--
yGenerator
Parts Item Standard Service limit
Stator Winding Resistance Stator Winding 1.8±10%Ωat 20℃--
Stator Auxiliary Winding 3.5±10%Ωat 20℃--
Rotor Excitation
Winding Resistance Excitation Winding 51.3±10%Ωat 20℃--
Carbon Brush Carbon Brush Length 10mm 6mm
8
POWER PRODUCTS

2. Periodic Maintenance
2.1 Service Intervals
Good maintenance is essential for safe, economical, and trouble-free operation. It will also help reduce air
pollution.
Exhaust gas contains poisonous carbon monoxide. Shut off the engine before
perform any maintenance. If the engine must be run, make sure the area is well
ventilated.
Periodic maintenance and adjustment is necessary to keep the generator in good operating condition.
Perform the service and inspection at the intervals shown in the Maintenance schedule below:
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WARNING
(1) Service more frequently when used in dusty areas.
(2) These items should be serviced by an authorized generator dealer.
(3) When more often use, only servicing according to above correct intervals can insure the generator set
long-term use.
9
POWER PRODUCTS

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10
POWER PRODUCTS
DIPSTICK
DRAIN BOLT
2-2 Routine Maintenance Procedures
2.2.1 Oil Change
Drain the used oil while the engine is warm. Warm oil drains quickly and completely.
1. Place a suitable container below the engine to catch the used oil, and then remove
the filler cap/dipstick and the drain plug.
2. Allow the used oil to drain completely, and then reinstall the drain plug, and tighten
it securely.
3. With the engine in a level position, fill to the outer edge of the oil filler hole with the
recommended oil.
2.2.2 Oil Filter Service
Remove the bolt that secures the filter and carefully pull the assembly toward
you.
The filter may be immersed in solvent then blown dry with compressed air.
Replace the filter at the scheduled service interval or anytime the screen is
damaged or all deposits cannot be removed.

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11
POWER PRODUCTS
2.2.3 Air Filter Service
Remove the air cleaner cover and inspect the filter. Clean or replace dirty filter elements.
Always replace damaged filter elements.
2.2.4 Fuel Filter Service
1. Drain out the fuel from the fuel tank. Turn the screw in the drain plug counter
clockwise until fuel flows. Use a suitable container to catch the fuel.
2. Remove the three screws securing the fuel cock assembly and remove the filter
from the housing.
FUEL TANK
DRAIN PLUG
FUELCOCK
FUELFILTER
ASSEMBLY

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12
POWER PRODUCTS
2.2.5 Adjust the valve clearance
(1) The clearance must be adjusted when the engine is cold.
timiLecnanetniaMdradnatS --mm51.ecnaraelctsuahxE/ekatnI
(2) Valve timing
CDTerofeb°41nepO
Intake Close 50°after BDCCDBerofeb°45nepO
Exhaust Close 10°after TDC

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13
POWER PRODUCTS
3. Engine disassembly and reassembly
3.1 Disassembly
3.1.1Fueltank
1. Release the joint between the fuel line and fuel tank.
2. Release the hose clamp of the fuel line on the pump side.
3. Remove the tank.
3.1.2 Exhaust Muffler
1. Remove the flange bolt
2. Remove the set bolt
3. Discard the muffler gasket. Do not reuse.
3.1.3Aircleaner
(1). Disassemble the air cleaner cover.
(2). Pull out the element.
(3). Disassemble the air cleaner bottom case.
3.1.4 Recoil starter unit
(do not disassemble)
3.1.5Disassemblethefancover
Unbolt and remove the fan cover.
4.1.6 Starter pulley
Unbolt and remove

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14
POWER PRODUCTS
3.1.7 Air inlet pipe
3.1.8 Remove electric starter motor
3.1.9 Remove cylinder head cover
3.1.10 Valve rocker arm seat
3.1.11 Push rods
3.1.12 Fuel injector
(1) Remove the high-pressure fuel line.
(2) Remove fuel injector.
(3) Be careful not to damage the nozzle washer and spacer.

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15
POWER PRODUCTS
3.1.7 Air inlet pipe
3.1.8 Remove electric starter motor
3.1.9 Remove cylinder head cover
3.1.10 Valve rocker arm seat
3.1.11 Push rods
3.1.12 Fuel injector
(1) Remove the high-pressure fuel line.
(2) Remove fuel injector.
(3) Be careful not to damage the nozzle washer and spacer.

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16
POWER PRODUCTS
3.1.13 Remove the cylinder head
3.1.14 Remove the injection pump
(1) Remove the pump together with the base.
(2) Ensure the hooking part of control lever is at the meshing position before
disassembling.
(3) Pull out the flat tappet remaining inside the housing
3.1.15 Crankcase cover
(1) Remove the engine oil injection pump cover.
(2) Remove the engine oil filter cover.
(3). Remove crankcase cover.

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17
POWER PRODUCTS
tfahsmaC61.1.3
(1) Remove the camshaft taking care not to damage the oil seal.
(2) Note the position of the timing mark
(3) Remove and store the intake and exhaust tappets separately.
3.1.17 Remove balance shaft
3.1.18 Piston and connecting rod assembly
(1) Dismount the forcing nut of connecting rod.
(2) Remove the big end cap of connecting rod.
(3)Turnthecrankshafttothetopofstrokeandtakeoutthepiston.
- Remove carbon from the upper inner surface of cylinder barrel before removal.
.