Hyundai HCP6500D User manual

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Diesel-Powered Generator
User Manual

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©2011 Hyundai Power Equipment. All Rights Reserved.
Licensed by Hyundai Corporation, Korea.
HCP6500D-0711-02

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Thank you for purchasing this Hyundai Power Equipment
Generator.
Please register in order to ensure warranty service in the future.
This manual covers the safety, operation and maintenance
procedures for the HCP6500D Diesel Generator.
All information in this publication is based on the latest
product information available at the time of print. Visit www.
powerbyhyundai.com for manual updates and operation
notices.
No part of this publication may be reproduced without written
permission. Please keep this manual together with the Owners
Card. Contact Hyundai Power Equipment at the numbers listed
on the Owners Card if warranty service is required.
It is important that anyone operating this product read and
understand the manual prior to use.

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Warranty Information
Warranty service, operation assistance and product support is provided by
Midland International Inc., a licensed manufacturer of Hyundai Power Equipment.
www.powerbyhyundai.com
TECHNICAL ASSISTANCE
1-855-706-8475
CUSTOMER SERVICE
1-877-528-3772 (toll-free)
SALES
1-503-534-3684
Component Certifications
This product contains components certied by the following agency:

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TABLE OF CONTENTS
1.0 - OPERATION SAFETY
1.1 - Operation Safety 8
1.2 - AC Safety Guidelines 9
1.3 - Maintenance Safety 9
1.4 - Other Safety Hazards 10
2.0 - COMPONENTS
2.1 - Identication 11
3.0 - PRE-OPERATION INSPECTION
3.1 - Engine Oil Check 15
3.2 - Fuel Level Check 16
3.3 - Air Filter Check 17
4.0 - OPERATION
4.1 - Before Starting 18
4.1.2 - Connecting Battery 18
4.2 - Starting the Generator 20
4.3 - Using the Generator 22
4.4 - Stopping the Generator 25
5.0 - MAINTENANCE
5.1 - Importance of Maintenance 26
5.2 - Maintenance Schedule 26
5.3 - General Inspection 27
5.4 - Air Filter Service 27
5.5 - Oil Maintenance 28
5.6 - Fuel Filter Cleaning 29
5.7 - Checking Battery Charge 29
5.8 - Handling and Storage 30
6.0 - TROUBLESHOOTING 32
7.0 - SPECIFICATIONS 33
8.0 - WIRING DIAGRAMS 34
WARRANTY 35

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1.0 - SAFETY
1.1 - Operation Safety
• Always perform a pre-operation check before starting the engine.
• Properly clean and maintain the equipment.
• Operate the generator according to instructions for safe and dependable
service.
• Before operating the generator, read the user manual carefully.
Otherwise, it may result in personal injuries or equipment damage.
• Never run the generator in an enclosed area to avoid harm from exhaust
emissions of a poisonous carbon monoxide gas.
• Be careful not to touch the exhaust system or discharge tubing during
operation due to risk of burns.
• Pay attention to the warning labels. The engine exhaust system will
become heated during operation and remain hot immediately after the
engine is stopped.
• Diesel fuel is a ammable and explosive liquid. Refuel in a well ventilated
area with the engine stopped.
• When refueling the generator, keep it away from cigarettes, open ames,
smoke and/or sparks.
• Connections for standby power to a building’s electrical system must be
done by a qualied electrician and must comply with all applicable laws
and electrical codes. Improper connections may cause serious injuries
to electrical workers during a power outage, and when the utility power
is restored, the generator may explode or cause res.
• Place the generator at least 3ft away from buildings or other equipment
during operation.
• Run the generator on a level surface. If the generator tilts, fuel spillage
may result.
• Know how to stop the generator quickly and understand operation of
all the controls. Never permit anyone to operate the generator without

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proper instructions.
• Keep children, pets and machinery with rotating parts away during
operation.
• Do not operate the generator in rain or snow.
• Do not allow any moisture to come in contact with the generator.
1.2 - AC Safety Guidelines
Before connecting the generator to an electrical device or power cord:
• Make sure that everything is in proper working order. Faulty devices or
power cords can lead to an electrical shock.
• Turn off the generator immediately if the device begins to operate
abnormally. Then disconnect the device and investigate the problem.
• Make sure that the electrical rating of the device does not exceed that of
the generator. If the power level of the device is between the maximum
output power and the running power of the generator, the generator
should not be used for more than 30 minutes.
• The connections from the generator to the household power supply
should be done by professional electrical technicians. Improper
connections may lead to a re hazard or damages to the generator set.
1.3 - Maintenance Safety
• After any maintenance is performed, wash immediately using soap and
clean water because repeated exposure to lubricant may cause skin
irritation.
• Do not clean the lter element with ammable liquids like gasoline
because explosion may occur.
• Turn off the generator set before performing any maintenance.
Otherwise it can cause severe personal injury or death.
• Allow the generator set to cool down before performing any
maintenance.
• Always wear safety glasses when cleaning the generator set with air.
• Do not clean the generator set with a pressure washer because it can

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cause damage to the generator set.
• Before working with batteries, ventilate the area, wear safety glasses, do
not smoke and always disconnect the negative cable rst and reconnect
it last.
• Use rubber gloves when coming into contact with engine oil.
• Always stop the generator set before removing the oil ller cap.
• Only qualied maintenance personnel with knowledge of fuels,
electricity, and machinery hazards should perform maintenance
procedures.
1.4 - Other Safety Hazards
• To avoid breathing in poisonous carbon monoxide from the exhaust
gases, adequate ventilation should be provided if the generator set is
running in a partially enclosed space.
• If the generator set is stored outdoors, check all the electrical
components on the control panel before each use. Moisture can
damage the generator and can lead to an electric shock.

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COMPONENTS
2.1 - Identification of Components

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3.0 Pre-Operation Inspection
Exhaust gas contains poisonous carbon monoxide. Never run the generator
in an enclosed area. Be sure to provide adequate ventilation. Operate the
generator on a level surface. If the generator is tilted, fuel spillage may result.
Keep away from rotating parts while the generator is running. The generator is
air-cooled and may be damaged if ventilation is not adequate.
Do not touch the alternator while the generator is operational. Do not operate
in fog, high-humidity or rain. Ensure proper grounding prior to starting the
generator.
3.1 - Engine Oil Check
Generator engine ships without oil - add oil before starting for the first time and
check oil before every subsequent use. Engine oil is a major factor affecting
engine performance and service life. Non-detergent or vegetable oils are not
recommended.
1. Ensure the generator is on a level surface.
2. Inspect engine oil:
• Take out the oil ller cap and clean the dipstick.
• Check the oil level by reinserting the oil ller cap without rotating it.
Remove the oil ller cap and examine the oil level. If the oil level is at
or below the lower level, rell the oil to the upper limit mark. (10W30)
Reinsert the oil ller cap and tighten securely. (Refer to gure)

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3.2 - Fuel Level Check
1. Check the fuel level by reading the gauge or removing the fuel tank cap
to visually check the level.
2. Refuel if level is too low. Tighten the fuel tank cap securely after relling.
Refuel in a well-ventilated area with the engine stopped. Do not smoke or
allow open flames or sparks in the area where the generator is being refueled
or where diesel is stored. Do not overfill the tank. Be careful not to spill fuel
when refueling. Wipe up any spilled fuel and let the area dry before starting
the engine.
Diesel substitutes such as biodiesel are not recommended. They may be
harmful to the fuel system components.

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3.3 - Check the Air Filter
1. Remove the metal cover on the canopy.
2. Remove the screw on the outside of the air lter cover.
3. Remove the screw on the air lter element and carefully remove the lter
element.
Air filter should be checked and cleaned according to the Maintenance
Schedule. Always inspect air filter before using the generator. Clean Air Filter
every 3 months or after 50hrs of operation according the Air Filter Service
procedure.

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4.0 - OPERATION
4.1 - Before Starting
1. Disconnect all devices prior to starting the generator set
2. Ensure that the engine switch is in the OFF position.
3. Ensure that the circuit breaker is in the OFF position.
4. Properly ground the generator set
5. Ensure that the throttle of the engine is in the STOP position
CHECK FUEL PIPING
This generator ships without fuel or oil inside the engine.
• Inspect fuel lines for air prior to lling up with fuel: drain air by removing
the screw on the fuel pump and slowly lling the pump until no more air
comes out.
CONNECTING THE ELECTRIC START BATTERY
1. Connect the red cable with the positive terminal of the battery. Ensure
the connection is secured by using the fastener at the battery terminal.
2. Connect the black cable with the negative terminal of the battery. Ensure
the connection is secured by using the fastener at the battery terminal.
Ensure that the battery has been connected properly prior to startup. Do
not reverse the polarity of the terminals when charging the battery. Serious
damage to the generator and/or battery may occur. Do not attempt to connect

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the battery while the generator engine is running. Disconnect the cables from
the battery while the generator is in storage.
This generator runs on diesel fuel. Wipe off any spilled fuel immediately and
before using the generator. Do not use gasoline, biodiesel, kerosene or ethanol
fuels as these can permanently damage the engine. Do not operate indoors
or in areas with restricted ventilation. Keep a safe area of 6 feet around the
generator when it is in operation.
Do not touch the generator casing or or place objects on top while it is in
operation. Do not operate in wet or foggy environments. Do not smoke near or
around the generator while it is in use or in storage.To ensure a longer engine
life, it is recommended that the engine runs for 30 hours prior to connecting a
full load. This breaking-in period allows manufacturing defects to be detected
prior to critical use.
GROUND TERMINAL
Before using generator, a ground wire must be connected to the ground terminal.
The Ground terminal is located on the Front Panel. Before using the ground terminal
consult a qualied electrician.
Ground Terminal Symbol:
The HCP6500D generator can be started using three methods.
• Electronic Start Method,
• Remote Start Method

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4.2 - Starting the Generator Set
ELECTRIC STARTING METHOD
Batteries produce explosive gases. Keep sparks, flames and cigarettes away
from the battery. To prevent the possibility creating sparks near the battery,
connect the charging cables to the battery terminals first, then to the generator.
When disconnecting, remove cables at generator first.
1. Disconnect all devices from the generator prior to starting.
2. Turn throttle to the RUN position.
3. Press the circuit breaker to the OFF position.
4. If engine is cold, press and hold the heater button for approximately 30
seconds.
5. Turn engine switch ON and push the engine ignition button until the
generator starts. Do not push the ignition button for more than 10
seconds. Wait one minute between ignition attempts.
If electric start does not turn of the generator after three attempts, contact
customer support. Repeated attempts could damage the ignition mechanism.
6. Allow engine to run for approximately 2 minutes before connecting a
load. After the engine has warmed up, press the circuit breaker to the
ON position.