Hyundai DHY6000SE User manual

DIESEL GENERATOR - 3000rpm Models
DHY6000SE/LR --- DHY8000SE/LR DHY8000SELR-T
User Manual
Licensed by Hyundai Corporation, Korea

Page 2
Rev 3

CONTENTS
Section Description Page No/No’s
1. SAFETY 3 - 7
2. MACHINE LAYOUT 7 - 8
3. PREPARATION for STARTING 8 - 11
4. OPERATING THE GENERATOR 12 - 14
5. LOAD 14 - 15
6. STOPPING THE MACHINE 15
7. PERIODIC MAINTENANCE 16
8. LONG TERM STORAGE
17
9. TROUBLE SHOOTING 18
10. SPECIFICATIONS 19
11. WIRING DIAGRAM 20
12. SERVICE RECORD SHEET 21
13. GENPOWER CONTACT DETAILS 22
14. DECLARATIONS OF CONFORMITY 23
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1. SAFETY
1.1. General safety notes.
1.1.1. 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. Keep the manual safe and pass
it on if the machine is loaned or sold to another user.
1.1.2. Please note the following safety points.
1.1.2.1. The machine should never be left it in a condition which would
allow an untrained or unauthorised person/s to operate this machine.
1.1.2.1.1. 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.
1.1.2.1.2. Some or all of the following - warning signs, symbols
and/or PPE pictograms may appear throughout this manual.
You MUST adhere to their warning/s. Failure to do so may
result in personal injury to yourself or those around you.
The FOLLOWING safety notes will help avoid or reduce risk of injury ordeath.
Indicates a hazard, which, if
not avoided, could result in
serious injury or death.
Indicates a hazard, which, if
not avoided, could result in
serious injury.
Indicates a hazard which, if
not avoided, might result in
minor or moderate injury.
Indicates a situation that
could easily result in
equipment damage.
READ and keep the manual
safe and pass it on if the
machine is loaned or sold
to another user.
You MUST fully read
instructions to make sure
you use and operate
machine safely.
Appropriate Personal Protective Equipment (PPE)
MUST be worn at all times when machine is in use or being repaired.
ALWAYS keep the working area clear of non-essential people to include, but not
limited to, children, the elderly and vulnerable persons.
NEVER ALLOW an untrained person to use this machine.
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1.2. Carbon monoxide (where applicable).
1.2.1. Carbon monoxide is a colourless and odourless gas. Inhaling this gas can cause
death as well as serious long term health problems such as brain damage.
1.2.2. The symptoms of carbon monoxide poisoning can include but are not limited
to the following;
1.2.2.1. Carbon monoxide poisoning symptoms are similar to flu, food
poisoning, viral infections and simply tiredness. It is quite common for
people to mistake this very dangerous poisoning for something else.
1.2.2.2. To avoid carbon monoxide poisoning DO NOT use Petrol/Diesel-
powered equipment inside any of the following;
This list is not exhaustive and if you are in any doubt contact your dealer.
1.2.3. If you think you have or someone around you has been affected by carbon
monoxide poisoning;
1.2.3.1. Get them fresh air immediately, by leaving the affected area or by
opening doors and windows. If safe and practical to do so make sure that
the machine is turned off. DO NOT enter a room you suspect of having
carbon monoxide present – instead call the emergency services.
1.2.3.2. Contact a doctor immediately or go to hospital - let them know that
you suspect carbon monoxide poisoning.
1.2.4. DO NOT use in an enclosed area or a moving vehicle.
Home, garage, tent, camper van, mobile home,
caravan or boat.
Headaches, dizziness, nausea, breathlessness,
collapsing or loss of consciousness.
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1.3. General fuel safety.
ALL FUELS ARE FLAMMABLE
1.3.1. Fire hazard - keep fuel away from all sources of ignition for example
heaters, lamps, sparks from grinding or welding.
1.3.2. DO NOT carry out hot work on tanks that have contained fuel it
is extremely dangerous.
1.3.3. ALWAYS keep work area clean and tidy.
1.3.4. ALWAYS clean up all spills promptly using correct methods i.e.
absorbent granules and a lidded bin.
1.3.5. ALWAYS dispose of waste fuels correctly.
1.4. Fueling/De-fueling (where applicable).
ALL FUELS ARE FLAMMABLE
1.4.1. ALWAYS fuel and defuel in a well-ventilated area outside of buildings.
1.4.2. ALWAYS wear correct, suitable and fit for purpose Personal Protective
Equipment (PPE), suggested items are but not limited to safety gloves
and overalls.
1.4.3. When fueling/de-fueling ALWAYS avoid inhaling fumes
1.4.4. When de-fueling ALWAYS use a propriety fuel retriever.
1.4.5. ALWAYS carry fuel in the correct and clearly marked container.
1.5. Electrical safety.
1.5.1. Electricity can kill - NEVER work on LIVE/ENERGISED equipment.
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1.5.2. Prior to carrying out any maintenance work you MUST Identify electrical
isolation methods and isolate all electrical supplies,
1.5.3. Prior to use and with all electrical supplies isolated You MUST check all
electrical cables, plugs and connections for the following;
1.5.3.1. Are intact and have no signs of damage, to include but not limited to
bare wires, chaffing, cuts and loose wiring.
1.5.3.2. If there are any signs of damage, the damaged item MUST be taken
out of service until the damage has been repaired by an electrically
competent person.
1.5.3.3. All trailing cables should be routed so as not to cause any kind of trip
hazard.
1.5.3.4. NEVER work on or near electricity with wet hands, wet clothing, and
wet gloves.
1.6. Batteries
1.6.1. Batteries present a risk if they become damagedby the possible leaking of
electrolyte. This electrolyte is an acid and can cause serious burn injuries. Care
should be taken when working on or near them. NOTE the electrolyte may be in
liquid or gel form.
1.6.2. Should you come into contact with electrolyte you should;
1.6.2.1. Remove all clothing contaminated with electrolyte. If you cannot
remove then saturate in water.
1.6.2.2. Get medical assistance as soon as possible. You must advise the
medical staff of the type acid.
1.6.2.2.1. Lead/acid battery = dilute sulphuric acid
1.6.2.2.2. Nickel/cadmium = potassium hydroxide alkali electrolyte.
1.6.2.3. Use fresh running water to wash off excess electrolyte, continue this
until medical assistance arrives. Make sure that you do not wash the
electrolyte to another part of the face or body.
1.6.2.4. If electrolyte comes into contact with Eyes the electrolyte needs to be
immediately washed away with large amounts of water. Make sure that you
do not wash the electrolyte to another part of the face or body.
1.6.3. Gasses from charging batteries are highly flammable and great care should
be taken to charge in well ventilated areas.
1.6.4. There is an explosion risk if the battery terminals are short circuited, when
connecting/dis-connecting ALWAYS exercise great care sothat the terminals
or battery leads are NOT allowed to touch and cause a spark.ALWAYS use
suitable insulatedtools.
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1.7. Vibrations (where applicable).
1.7.1. Prolonged use of hand held (operated) machines will cause the user to feel the
effects of/from vibrations. These vibrations can lead to white finger (Raynaud's
phenomenon) or carpal tunnel syndrome. This condition reduces the ability of
the hand to feel and regulate temperature, causing numbness and heat
sensations and may cause nerve damage and circulatory tissue death.
1.7.2. Not all factors that lead to white finger disease are known, but cold weather,
smoking and other diseases that affect blood vessels and blood circulation as
well as large and long-lasting impact of shocks are considered factors in the
formation of white finger. Note the following to reduce the risk the white finger
and carpal tunnel syndrome:
1.7.2.1. Wear gloves and keep your hands warm
1.7.2.2. Take regular breaks
1.7.3. All of the above precautions may help reduce the risk of white finger disease
but not rule out carpal tunnel syndrome. Long-term and regular users are
therefore recommended to observe the condition of your hands and fingers.
Seek medical attention immediately if any of the above symptoms should occur.
1.8. Noise.
1.8.1. The operating noise of the machine can damage your hearing. Wear hearing
protection such as earplugs or ear defenders to protect your hearing. Long-
term and regular users are advised to have hearing checked regularly. Be
especially vigilant and cautious when wearing hearing protection because your
ability to hear alarm warnings will be reduced.
1.8.2. Noise emissions for this equipment is unavoidable. Carry out noisy work at
approved times and for certain periods. Limit the working time to a minimum.
For your personal protection and protection of people working nearby it is also
advisable for them to wear hearing protection.
1.8.3. See CERTIFICATE of CONFORMITY section for Outdoor Noise declaration of
conformity.
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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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1.5. 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 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
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.
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.
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2. MACHINE LAYOUT
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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 refueled or where the fuel is stored.
•Do not overfill the diesel tank and make sure the filler cap is
securely closed after refueling.
•Take care not to spill fuel when refueling. 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
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.
• Always check the engine oil level with the generator on a flat,
level surface before starting or refilling the machine.
Typical control panel layout for Single phase machine.
Typical control panel layout for Single & Three phase machine.
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•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.
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 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.
3.3. Service 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, otherwise
rapid engine wear will result.
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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
cover and screw on the
nut.
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.
•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.
3.5.1.1. 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. Replace the engine oil whilst the engine is warm, after 20-hours running.
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 given off when charging battery. Only charge
in a well-ventilated area, away from sparks and naked flames.
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 a voltmeter - check the voltage is 12.3V+, if lower, the battery 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 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
• 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
(turn anti-clockwise).
4.1.4. Set the engine speed lever is set to ‘RUN’.
4.1.5. Turn the starting key clockwise to the 'START'
position.
4.1.6. Remove your hand from the key as soon as the
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.
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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’.
• 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 refuel the fuel tank whilst the engine is still running.
4.2. Wireless remote controlled start (where fitted).
4.2.1. With the ignition switch in the OFF position, and the machine in all other aspects ready
for operation (see user manual).
4.2.2. The remote control has an approximate range of 25 metres in line of sight with no
obstructions. This distance will reduce as the battery power depletes.
4.2.3. Pull back the protection shroud (4) to reveal the ON – OFF control buttons (1&3)
4.2.4. To start the machine press button (3) twice each time the tell-tale LED (Blue) will light.
N.B. the first press arms system, second press starts machine.
4.2.5. The machine will crank 3 times until started, if there is a NO start then a pause of 3
seconds,
4.2.6. The machine will crank 5 times until started, if there is a NO start then a pause of 3
seconds,
4.2.7. The machine will crank for 7 times until started, if there is NO start the machines wireless
receiver will emit a ‘beeping sound’. You will now have to turn the machine OFF and back
on to reset the wireless receiver.
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4.2.8. The following are possible causes for a NO start,
4.2.8.1. STOP/START lever in STOP position.
4.2.8.2. Emergency STOP button activated.
4.2.8.3. Low or no fuel.
4.2.8.4. Flat battery.
4.3. Checks whilst generator is running.
4.3.1. After each use make sure that there are no abnormal sounds or vibration.
4.3.2. Check that the engine is running smoothly normally.
4.3.3. Check that there is no excessive smoke fromthe exhaust after 10 minutes of
running, and the engine has reached working temperature
4.3.4. 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
• 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.
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.
5.1.5. If the generator is overloaded the main breaker will trip.
Lamp
Illuminated Indicating
V
Voltage
Hz
Frequency
V1
Event timer - or current
running time (hours).
This will reset to zero
when main Breaker is
'OFF'
V2
Total Run Time
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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.
5.2. 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 FluorescentLamp 80 vA 40 to 60 vA
Motor
Driven
Equipment
x 3.5 x 1 to 2
Refrigerator,
Electricfan,
Compressor or
grinder
Refrigerator150
watts
450 to 750
vA
150 to 30
vA
6. STOPPINGMACHINE
•Do not stop the engine suddenly or whilst under load.
•This can damage the 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 or pull down the stop lever.
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7. PERIODICMAINTENANCE
• 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.
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
Check and tighten head bolts
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
Yes –
First time
Yes
Grind intake/exhaust valves
Yes
Replace piston rings
Yes
Check battery condition
Yes
Check carbon brushes and slip rings
Yes
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. 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.
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.
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