Hyundai HY12000LE User manual

PETROL GENERATOR
Models HY12000LE & HY12000LE-3
User Manual

Page 2
CONTENTS
Section Description
Page No/No’s
1. SAFETY
3 - 6
2. MACHINE LAYOUT
6
3. PRE-OPERATION CHECKS
7 –8
4. OPERATION
8 –10
5. STARTING THE ENGINE
10 –11
6. STOPPING THE ENGINE
11
7. USING THE MACHINE
11 –13
8. BATTERY
13 - 14
9. PERIODIC MAINTENANCE
14 –17
10. TROUBLESHOOTING
18 –19
11. STORAGE
19
12. SPECICIFATIONS
20
13. WIRING DIAGRAMS
21 –22
14. CONTACT DETAILS
23
15. DECLARATIONS of CONFORMITY
24

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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 –FOLLOW safety messages to avoid or reduce risk of injury or death.
DANGER - indicates a
hazard which, if not
avoided, could result in
serious injury or death.
WARNING - indicates a
hazard which, if not
avoided, could result in
serious injury or death.
CAUTION - indicates a
hazard which, if not
avoided, might result
in minor or moderate
injury.
NOTE - indicates a
situation that could
easily result in
equipment damage.
READ MANUAL
1.3. Carbon Monoxide
1.3.1. Carbon monoxide is colourless and odourless, inhaling 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.
Personal Protective clothing (PPE)

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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.
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.

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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.
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. Get medical assistance as soon as possible.
1.4.10.6.1.2. Remove all clothing contaminated with acid.

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1.4.10.6.1.3. Use fresh running water to wash excess acid, continue this
until medical assistance arrives.
1.4.10.6.1.4. Eye contact with acid needs to be 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 m from buildings or other equipment, or the
engine may overheat.
1.5.1.6. Avoid operating the engine with a dust cover.
2. MACHINE LAYOUT
1
Frame.
2
Fuel Cap.
3
Fuel Gauge.
4
Exhaust.
5
Oil Cooler.
6
Fuel Valve.
7
Choke.
8
Engine Switch.
9
Voltmeter.
10
Spark Plug Cap.
11
Oil Drain Bolt.
12
Air Filter.

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3. PRE-OPERATION CHECKS
Pre-operation checks should be carried out each time the generator is
used.
3.1. Check engine fuel.
3.1.1. Check fuel level at fuel level gauge.
3.1.2. If fuel level is low –refill with fresh unleaded petrol.
3.1.3. Make sure you use the fuel filter screen on the fuel filler neck.
3.1.4. Fuel tank capacity;
Model
Full
HY12000LE, HY12000LE-3
25 Litres
DO NOT refill tank while engine is running or HOT.
3.1.5. Close fuel tap before re-fuelling.
3.1.6. DO NOT allow any dust, dirt, water or any other foreign objects get into the fuel or
fuel tank.
3.1.7. Wipe off any spilt fuel thoroughly before starting the engine.
3.1.8. Keep all sources of ignition and naked flames away from the area in which you are
fuelling machine.
3.2. Check Engine oil
3.2.1. Before checking oil make sure generator is put on stable and level ground.
3.2.2. Remove dipstick and wipe with a clean rag, check engine oil level should be between
low and full marks on dipstick.

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3.2.3. If oil level is below the lower level line, refill with 15W 40 oil to the upper level.
Change contaminated oil.
3.2.4. Oil Capacity
Model
Full
HY12000LE, HY12000LE-3
1.5 Litres
4. OPERATION
4.1. Engine switch.
4.1.1. “RUN” indicates the engine in “RUN” position, “OFF” indicates the engine in “OFF”
position, “START” indicates the engine in “starting” position.
You must always turn engine switch to OFF position when generator is
not in use.
4.2. Fuel valve.
4.2.1. The fuel valve is used to control the fuel flow from the tank to the carburetor. After
stopping the engine, the fuel valve should turn to “Off” position.

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4.3. Choke button.
4.3.1. The choke button is used to provide mixed gas with rich fuel to the engine when it is
in cold start. When the engine runs normally, push it to “open” position.
4.4. AC circuit breaker.
4.4.1. Overload current will make the circuit breaker trip out automatically.
4.4.2. It is required to prevent the generator set from short circuit or overload.
4.4.3. If the circuit breaker drops out. DO NOT turn on the circuit breaker without first
checking for overload and/or short circuits.
4.5. Grounding terminal (Earth connection).
DO NOT use generator without first connecting to ground/earth
connection.
4.5.1. The grounding terminal (Earth connection) is a special terminal which is used to
connect the generator to the ground properly.

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4.6. Engine protection system.
4.6.1. The engine protecting system is designed to protect engine from damage because of
lack of oil in the crank case.
4.6.2. When the engine oil in crank case is lower than the safe level line, the engine
protecting system will stop the engine automatically, even if the engine switch is still in
“run” position.
4.6.3. This will assist in protecting the engine from lack of oil.
5. STARTING THE ENGINE
Before starting the engine;
Turn ‘OFF’ the AC switch.
DO NOT connect any electrical appliances to the machine.
5.1. Turn the fuel tap to ‘ON’ position.
5.2. Turn the engine switch to ‘RUN’
5.3. Pull the choke lever to the ‘’CLOSED” position. Not necessary when engine is warm.
5.4. Turn the start switch to “START” position.
Do not keep the switch in the “START” position for more than 5 seconds,
or the starter may be damaged.
If the engine does not start at the first time, try a re-start after waiting
for a 10 second pause.
If the starter turnover speed degrades after time, it means that you will
need to charge the battery.

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5.5. After starting the engine, release the “START” switch immediately, the switch will return
back to “RUN” position.
5.6. After warming up the engine, push the choke button to “OPEN” position.
6. STOPPING THE ENGINE
If an emergency stop is required, turn the engine switch to “OFF”
position.
6.1. Turn “OFF” all appliances.
6.2. Turn off the AC circuit breaker.
6.3. Turn the engine switch to the “OFF” position.
6.4. Turn the fuel valve to the “OFF” position.
7. USING THE MACHINE
7.1. Environmental requirements.
7.1.1. Ambient temperature range, -15°C to +40 °C
7.1.2. Humidity level, <95%.
7.1.3. Serviceable elevation < 1000 m. If using at heights over 1000 m, the rated output
power will decrease.
7.2. Connection to power supply.
DO NOT Connect the generator to Mains AC sockets in your building –
commonly known as ‘back feeding’ it is extremely dangerous and illegal.
When the generator is being used as a backup power supply in the event
of a power failure. The installations should be carried out by an
electrician or authorized person.
Once load is connected to the generator, a careful inspection must be
performed to check for reliable connections and safety. Failure to do so
may result in damage to the generator or firing because of incorrect
connection.

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7.3. Generator grounding (Earthing).
DO NOT use generator without first connecting to ground/earth
connection.
7.3.1. The grounding terminal (Earth connection) is a special terminal which is used to
connect the generator to the ground properly.
7.4. Alternating Current (AC).
Overloading of your generator will shorten its service life.
7.4.1. Before starting the generator, you must confirm that the total power of the
appliances do not exceed the rated power of the generator.
7.4.2. When connecting loads to generator set, it is recommended that you turn on the
appliance with the maximum current first, then turn on the next lowest current and so
on.
7.4.3. In general, capacitive and inductive loads will need greatest starting current, when
they are turned on, especially electric motors.

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7.4.4. The following table indicates the parameter of the appliances for your reference
Type
Watt
Typical appliances
Example
Start
Rated
Appliances
Start
Rated
Filament lamp
Heater
X1
X1
Filament lamp
Filament lamp
100W
100VA (W)
100VA (W)
Fluorescent
lamp
X2
X1.5
Fluorescent lamp
Fluorescent lamp
40W
80VA (W)
60VA (W)
Equipment
with Motors
X3 - 5
X2
Refrigerator
Electric fan
Refrigerator
150W
450 - 750VA (W)
300VA (W)
7.5. Use at high elevation.
If a carburetor for high elevation use is used in a low elevation area, the
engine power will be degraded, engine will overheat or damaged
severely because of rarefied gas mix.
7.5.1. In high elevation area, the standard carburetor will give an over-rich gas mix to the
engine, thus, the output power degrades, and the fuel consumption increases.
7.5.2. If you intend to use the engine at an elevation over 1000m, we recommended you
have the carburetor replaced by an authorised dealer.
7.5.3. Even with a suitable carburetor, the engine power will degrade about 3.5%/300m.
8. BATTERY
8.1. The battery is a 12 volt 20Ah sealed lead acid battery and requires no maintenance other
than;
8.1.1. Ensure battery terminals are;
8.1.1.1. Kept clean.
8.1.1.2. Kept tight.
8.1.1.3. Covered to prevent short circuiting.

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8.1.2. 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 as soon as
possible. Make sure that all battery acid spills are correctly cleaned up straight away.
8.2. The battery should be stored in a charged condition.
8.3. Store in a dry place and should be recharge once a month.
8.4. It should not be stored at excessively high or low temperatures.
9. PERIODIC MAINTENANCE
There will be carbon monoxide emissions from the engine –see section
1.3.
STOP the machine before carrying out any kind of maintenance.
Improper maintenance or running the generator with faults may cause
damaged not covered by warranty.
Maintain the machine in accordance with the manual instruction.
9.1. Good maintenance and service gives an assurance that the generator will run safely,
economically and without any failures.
9.2. Maintenance chart.
Item
Remark
Pre-
use
check
Daily
Initial
and 1
Month
or 20
Hours
Every 3
Months
or 50
Hours
Every 6
Months
or 100
Hours
Every 12
Months
or 300
Hours
Spark Plug
Check condition,
adjust gap and clean
as necessary
●
Replace
Engine Oil
Check Oil level
●
Replace
●
●
Air Filter
Clean and replace if
necessary
●
More
often in
dusty
areas
Fuel Filter
Check filter, replace
as necessary
●
Valve clearance
Check and adjust
when engine is cold
●
Return
to dealer
Fuel Line
Check fuel hose for
cracks and damage.
Replace when
necessary
●

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9.3. Engine Oil replacement.
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.
Frequent and long term contact of oil with the skin may result skin
disease. Always wear suitable gloves and we recommend that when
finished work that you thoroughly wash your hands with soapy water.
9.3.1. Place a container under
the engine for containing
used oil. Then, remove the
dipstick and loosen the
draining screw and washer,
9.3.2. After draining the used
oil, reinstall the draining
screw and washer and
tighten them. In view of
environmental protection,
please take a proper way
to dispose the waste oil.
9.3.3. Take the waste oil to the
local recycling centre. Never dump waste oil on the ground, in ditches or drains.
Exhaust system
Check for leaks, re-
tighten or replace
gasket as required
●
Check silencer
screen, clean and
replace as required
●
Carburettor
Check Choke
operation
●
Cooling system
Check Cooling fan
for damage
●
Starting system
Check recoil starter
operation
●
De-carbonising
As necessary
●
All fittings and
fasteners
Check all fittings and
fasteners. If missing
or loose, replace
and tighten
●
●

Page 16
9.4. Air filter.
DO NOT clean the air filter element with petrol or inflammable solvent,
fire or explosion may occur.
Clean with soap water or non-flammable solvent.
DO NOT run the engine without the air filter elements fitted, it will result
in rapid wear of the engine.
9.4.1. Unscrew the cap nut, and remove the case.
9.4.2. Remove the washer, take out the paper
and foam elements.
9.4.3. Separate the paper element from the foam
one.
9.4.4. Check the elements and replace if
necessary. As a rule, when reaching the
period specified in maintenance schedule,
replace the paper element
9.4.5. Clean paper element,
9.4.5.1. Tap the element several times to
remove dust deposited on it or blow out
with high pressure air-line from inside to
outside of the
9.4.5.2. Never remove the dust with brush,
or the dust will enter the fibres and
block the vent holes.
9.4.6. Clean foam element,
9.4.6.1. Clean the foam element with soapy
water rinse and dry it or clean it with
high fire-point solvent and allow it to
dry.
9.4.7. Clean air cleaner bracket and case, prevent dust from sucking into the carburetor
along the inlet pipe.
9.4.8. Re-assemble the foam element and paper element.
9.4.9. Re-Install the case and tighten the cap nut.
9.5. Spark plug.
Never use incorrect spark plug.
9.5.1. It is recommended to use spark plug, F7TC or equivalent one.
9.5.2. Remove the spark plug cap.
9.5.3. Clean dust around the spark plug.
9.5.4. Unscrew the spark plug with a spark plug socket.

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9.5.5. Check spark plug. If the
electrode has damaged,
or isolator has broken,
replace the spark plug.
The clearance of the
spark plug electrode
should be 0.70mm -
0.80mm adjust the side
electrode as required.
9.5.6. Screw the spark plug
by hand carefully to
avoid damaging the
thread on the head.
9.5.7. When the spark plug is in position, tighten the spark plug with the special socket
wrench and depress the washer.
9.5.8. If install the used spark plug，after depressing the washer, retighten it 1/8-1/4 turn.
9.5.9. Reinstall the spark plug cap.
9.6. Clean fuel filter.
9.6.1. Close the fuel valve. Detach the depositing
cup and remove the “O” ring and screen.
9.6.2. Clean the depositing cup, the “O” ring and
screen with uninflammable or high flash-point
solvent.
9.6.3. Reinstall the “O” ring and the screen,
tighten the cup.
9.6.4. Open the fuel valve to check if there is any
leakage.
9.7. Fuel Tank Filter.
On completion make sure fuel filler cap is secured tightly.
9.7.1. Remove filler cap.
9.7.2. Remove fuel filter and clean with
solvent.
9.7.3. Wipe off and dry with a clean lint free
rag.
9.7.4. Replace filter into fuel tank.

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10. TROUBLESHOOTING.
10.1. Engine Troubleshooting - N.B. all corrective actions should be carried out by suitably
qualified person/s.
Condition
Possible cause/s
Corrective action/s
Engine will not
start.
Or
Low engine output.
Or
Engine runs
erratically
Insufficient
compression
Loose spark
Plug
- - - - - - - >
- - - - - - - >
Tighten plug properly
Loose
cylinder
head bolt
- - - - - - - >
- - - - - - - >
Tighten bolts properly
Damaged
gasket
- - - - - - - >
- - - - - - - >
Replace gasket
Sufficient
compression
No fuel to
combustion
chamber
Insufficient
pulling
speed on
recoil
starting
- - - - - - - >
Pull recoil starting rope
faster
Debris in
fuel tank
- - - - - - - >
Clean tank
Blocked
fuel line
- - - - - - - >
Clear blockage
No Fuel -
Poor fuel
- - - - - - - >
Fill with fresh fuel
Fuel valve
not Open
- - - - - - - >
Open fuel valve
Combustion
chamber
has fuel
No or poor
spark
Spark plug
dirty
Clean spark plug
Damaged
spark plug
Replace spark plug
Faulty
magneto
Consult dealer
Correct
spark
Improperly
adjusted
carburettor
Insufficient
pulling
speed on
recoil
starting
Pull recoil starting rope
faster
Incorrect
fuel
- - - - - - - >
- - - - - - - >
Check and replace fuel as
required
Overloading
- - - - - - - >
- - - - - - - >
Check and correct loading
Overheating
- - - - - - - >
- - - - - - - >
Check and correct cooling
system

Page 19
10.2. Generator Troubleshooting - N.B. all corrective actions should be carried out by
suitably qualified person/s.
Condition
Possible cause/s
Corrective action/s
Indicator light ON, no AC output
Circuit breaker tripped
Reset breaker
Poor connections or broken
wire/s
Check and repair.
Broken output socket
Faulty circuit breaker
Indicator light OFF, no AC output
Generator problem
Contact dealer
Indicator light OFF, no DC output.
Circuit breaker tripped
Reset breaker
Poor connections or faulty DC
power wires
Check and repair.
Generator problem
Contact dealer
Output power available - machine
running erratically
Engine RPM set too HIGH or
too LOW
With NO LOAD for 60 hertz set at
3780 RPM
With NO LOAD for 50 hertz set at
3150 RPM.
Otherwise Contact dealer
Loose components
Locate and tighten
Internal generator problem
Contact dealer
11. STORAGE
To avoid burn or fire by contact with the heated parts of the engine,
never pack or store the engine until it is has cooled down.
Petrol is highly flammable and explosive liquid.
After stopping the engine, drain fuel in a well ventilated area.
DO NOT allow naked flames or other sources of ignition to come into
contact with petrol or it vapours.
Long term storage of your machine will require some preventative measures to guard against the
effects of storage.
11.1. Fuel.
11.1.1. Drain the fuel tank, fuel tap (cock) and carburettor float bowl.
11.1.2. Pour a cup of SAE 10W 30 motor oil inside the tank, shake the tank to line with oil.
11.1.3. Drain off excess oil.
11.2. Engine.
11.2.1. Remove spark plug and pour about one table spoon of SAE10W 30 motor oil into
cylinder.
11.2.2. Start the engine allowing it to turn over..
11.2.3. Replace spark plug.
11.2.4. Clean exterior of the generator and apply a rust inhibitor.
11.2.5. Store generator in a dry well ventilated place with a cover over it.
11.2.6. The generator must remain in a level vertical position.

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12. SPECIFICATIONS
HY12000LE / LE-3
Engine
Model
HY680
Type
2 cylinder, 4 stroke, forced air cooling
Bore × stroke mm
78×71
Displacement ml
678
Compressed rate
8.5:1
Max output power
kW/(r/min) - Engine
14.7kW/3600rpm
Rated power kW/(r/min) -
Engine
10kW/3600
43.5/ 0(2500±200)
Ignition mode
Thyristor no-contact ignition
Start mode
Powered start
Lubricant capacity L
1.5
Fuel capacity L
25
Air cleaner element
Paper, foam element
Generator
Type
Synchronous generator
Volt regulation
Automatic voltage regulation
Rated voltage V
220/230/240
220/380 230/400 240/415
Phase
1 phase
1phase
3 phase
3 phase
Rated power kW
8.5
9.5
9
10
Max power kW
9.5
10.5
10
11
Rated frequency Hz
50
60
50
60
Power factor cos Φ
1.0
0.8
1.0
0.8
Generator set
Fuel consumption g/kW.h
≤360
Continuous working time h
6
Noise （7m away from
generator set）dB（A）
≤70
Standard configuration
Fuel tank, muffler, air cleaner, fuel indicator, multiple-
purpose meter, Oil warning system of generator set
Dimension（L×W×H）mm
930 x 830 x 960
Net weight Kg
164