Hyundai HY2800L-2 User manual

OPEN FRAME PETROL GENERATORS
Models - HY2800L-2, HY3800L-2, HY3800LEK-2,
HY7000LEK-2, HY9000LEK-2 &
HY10000LEK-2
User Manual

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Ver 2 - December 2016

CONTENTS PAGE NO/S
1. SAFETY 4 – 8
2. UNPACKING & ASSEMBLY 8 – 9
3. PARTS LOCATIONS 10
4. PREPARATION FOR USE 11 - 12
5. STARTING & STOPPING MACHINE 13 - 16
6. MAINTENANCE 17 – 20
7. STORAGE & TRANSPORTATION 21
8. SPECIFICATION 22
9. RECYCLING & PRODUCT DISPOSAL 23
10. DECLARATIONS of CONFORMITY 24
11. CONTACT DETAILS 25
12. MANUAL UPDATES 25
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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 thismachine.
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 beingrepaired.
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.
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 braindamage.
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 somethingelse.
1.2.2.2. To avoid carbon monoxide poisoning DO NOT use Petrol/Diesel-
powered equipment inside any of thefollowing;
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 emergencyservices.
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 movingvehicle.
Headaches, dizziness, nausea, breathlessness,
collapsing or loss of consciousness.
Home, garage, tent, camper van, mobile home,
caravan or boat.
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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 ofbuildings.
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 fuelretriever.
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 electricalsupplies,
1.5.3. Prior to use and with all electrical supplies isolated You MUST check all
electrical cables, plugs and connections for thefollowing;
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 (Not fitted onHY2800L-2/HY3800L-2 models).
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 orbody.
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. Noise.
1.7.1. 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.
1.7.2. 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.
1.7.3. See CERTIFICATE of CONFORMITY section for Outdoor Noise declaration of
conformity.
2. UNPACKING & ASSEMBLY
2.1. Unpacking.
2.1.1. Place the carton on a firm flat surface.
2.1.2. Remove everything fromthe carton except the generator.
2.1.3. Open the carton by carefully cutting the carton down each corner, being
careful not to cut the machine.
2.1.4. Leave the generator on the carton while you install the wheel kit.
N.B. TheHY2800L-2/HY3800L-2 versions DO NOT come with wheel kits.
2.2. Packing contents.
2.2.1. Owner’s manual – quantity 1.
2.2.2. Wheels – quantity 2.
2.2.3. Handle assembly – quantity 1.
2.2.4. Wheel axle – quantity 2.
2.2.5. Hardware bag comprising of;
2.2.5.1. Spark plug socket – quantity 1.
2.2.5.2. Socket bar – quantity 1.
N.B. The above packaging contents inthis manual are for reference only and do not
represent for any specific model.
2.3. Assembly.
2.3.1. The generator requires some assembly prior to first use.
2.3.2. The wheels are designed to give improvedthe portability.
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N.B. The wheels are NOT intended for on road use.
2.3.3. To install the wheels.
2.3.3.1. Slide the axle (2) through the wheel (1) from the outside then pass the
axle through the flat washer (3) and through the frame.
2.3.3.2. Once axle is passed through the frame put the ‘P’ clip (4) through the axle
hole.
2.3.4. To fit the rubber feet.
2.3.4.1. Pass the bolt (9) through the rubber pad (8) and support (7).
2.3.4.2. Pass the end of the M8 bolt (9) through the frame and secure it in place
with the M8 nut (6).
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3. PARTS LOCATIONS
3.1. Generic locations – locations may vary slightly between models.
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4. PREPARATION BEFORE USE
The machine is shipped without oil - You MUST add oil before using this machine.
4.1. Oil type – SAE15W40.
4.2. Adding oil.
4.2.1. Place the generator on a flat, level surface.
4.2.2.
Clean areaaround oil filler and remove oil cap and
dipstick. Wipe the dipstick clean.
4.2.3. Slowly fill the engine with oil through the oil
filler until it reaches the upper thread of the
filler hole or to the full mark on the dipstick.
4.2.4. Stop filling occasionally to check oil level. DO
NOT over fill.
4.2.5. Refit the oil filler cap and make sure the cap is tightened.
4.2.6. You MUST check engine oil level before starting every session.
4.3. Fuel type Unleaded Petrol.
4.4. Adding fuel.
Do not overfill the fuel tank you MUST allow space for fuel expansion. If thefuel tank is
overfilled, fuel can overflow onto a HOT engine andcause FIRE and/or EXPLOSION. If fuel
does spill,wait until it evaporates before starting engine. Check fuel lines, tank, cap and
fittings frequently forcracks or leaks. Replace as required.
4.4.1. DO NOT light cigarettes or smoke when filling the fuel tank. Fuel is
highly FLAMMABLE and it'svapours are EXPLOSIVE.
4.4.2. NEVER fill fuel tank when engine is running or hot. Turn generator engine OFF
and allow engine to cool entirely before filling fuel tank.
4.4.3. Avoid spilling petrol onto HOT engine.
4.4.4. Keep fuel away from sparks, open flames, pilot lights, heat, and other sources
of ignition.
4.4.5. DO NOT mix oil with petrol.
4.4.6. Once fueling has finished refit the fuel cap and fully tighten. Wipe up any
spilled fuel before starting machine.
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4.4.7. IMPORTANT: To prevent gum deposits from forming in fuel system parts such
as the carburetor, fuel hose ortank during storage. Alcohol-blended fuels
(calledgasohol), ethanol or methanol can attract moisture, which leads to
separation andformation ofacids during storage. Acidic gas can damage the
fuel system. Fuel should be emptied before storage for 30days orlonger. See
the “Storage” section. NEVER use engine orcarburetor cleaner products inthe
fuel tank as permanent damage may occur.
4.5. Grounding (Earthing) the generator.
4.5.1. The Requirement for Electrical Installations BS 7971:2008 requires that the
frame and external electrically conductive part ofthis generator be properly
connected to anapproved earth ground.
4.5.2. Proper grounding of the generator will help prevent electric shock in the
event of ground fault condition in the generator or in connected electrical
devices.
4.5.3. Proper grounding also helps dissipate static electricity, which often builds up in
ungrounded devices.
4.6. Floating earth portable generator use.
4.6.1. This range of generators adopt a floating earth configuration which means that
the Neutral of the alternator is not connected to the Earth of the machine.
4.6.2. It is therefore IMPORTANT that you ONLY use the generator to supply
equipment in the following combinations.
4.6.2.1. One or more of CLASS II equipment
4.6.2.2. Only ONE item of Class I equipment
4.6.2.3. One or more of CLASS II equipment and only ONE item of Class I
equipment.
4.6.3. CLASS I equipment has a GREEN/YELLOW earth wire connected inside the plug.
4.6.4. CLASS II equipment DOES NOT have GREEN/YELLOW earth wire connected
inside the plug.
4.6.5. CLASS II equipment will have the following symbol embossed or
printed on the casing.
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5. STARTING & STOPPING MACHINE
WARNING NEVER start orstop engine with electrical devices plugged into the power
outlets and devices turned on. Unplug all electrical loads from the unit’s power
outlets, or make sure that the main breaker is OFF (down) position, before starting
the engine.
5.1. Starting the engine – Recoil start.
5.1.1. On HY2800L-2/HY3800L-2
models press theengine switch (2
position switch) to ON position, on
HY3800LEK-2, HY7000LEK-2,
HY9000LEK-2 & HY10000LEK-2 models
press the engine switch (3 position
switch) to ON then to START position.
5.1.2. Turn the fuel tap to the ON position.
5.1.3. Move the engine choke lever tothe START position.
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5.1.4. For recoil start, firmly grasp the recoil handle
and pull slowly until increased resistance isfelt.
Then pull rapidly upandaway.
5.1.5. When the enginestarts, move choke lever to the
½ - choke position till engine runs smoothly and
then to RUN position. If engine falters, move
the choke lever back to½ - choke position until
engine runs smoothly and then fully RUN
position again.
Starter cord kickback (rapid retraction) will pull hand and arm toward engine faster than you
can let gowhich could cause broken bones,fractures, bruises, or sprains resulting in serious
injury. When starting engine, pull cord slowly until resistance is felt and then pull rapidly to
avoid kickback. NEVER wrap the starter cord around your hand.
If engine fails to start after 3 pulls, or ifunitshutsdown during operation. Make
sure the unit ison a flat level surface andcheck for proper oil level in crankcase. This
engine is equipped witha low oil level protection device.
5.2. For electric start.
If battery is discharged or unavailable, use manual starting instructions as above.
5.2.1. Follow steps 5.1.1. To 5.1.3.
5.2.2.
Press and hold the switch at
the “START” position until
generator starts.
5.2.3. To prolong the life ofstarter motor and starter components, DO NOT press
the start switch in the “START” position for more than 5 seconds, you MUST
then pause for at least 1minute between starting attempts.
5.2.4. When the engine starts, move the choke lever to ½ - choke position till engine
runs smoothly and thento RUN position. If the engine falters, move the
choke lever back to½ - choke position until engine runs smoothly and then
fully RUN position again.
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Exhaust system heat and/or gases could ignite combustible, structures ordamage the fuel
tank causing a fire, resulting in death, serious injury and/or property damage. Contact with
muffler area could cause burn resulting inserious injury.
DO NOT touch hot part and AVOID hot exhaust gases.
You MUST allow the equipment tocool before touching.
Keep atleast 5 feet (152 cm) ofclearance onall sides of generator including overhead.
IMPORTANT DO NOT overload the generator. DO NOT overload individual output sockets.
These outlet sockets are protected against overload with push-to-reset-type circuit
breakers. If current rating ofany circuit breaker is exceeded, that breaker will open and the
electrical output to that socket will belost.
5.3. Connecting electrical loads.
5.3.1. Let the engine run until the rpm is stable andhas been allowed towarm up for a
few minutes after starting.
5.3.1.1. Then plug in and turn on the electrical loads.
5.3.1.2. Add up the rated watts (or amps) of all loads to be connected
at one time. This total should not be greater than;
5.3.1.2.1. The circuit breaker rating of the output socket supplying the power
or,
5.3.1.2.2. The rated wattage/current capacity of the generator.
Connect all electrical loads in the OFF position then turn ON for operation.
Turn all electrical loads OFF and disconnect from generator before stopping generator. #
Exceeding generators wattage/current capacity could damage generator and/or electrical
devices connected to it.
DO NOT exceed the generator’s wattage/current capacity.
# Failure to disconnect the electrical load before switching the generator OFF may
damage the AVR.
5.4. Overloading.
5.4.1. Overloading a generator in excess of its rated wattage capacity can result in
damage to the generator and to connected electrical devices.
5.4.2. Observe the following to prevent overloading of the unit;
5.4.2.1. Add up the total wattage of all electrical devices to be connected at one
time. This total should NOT be greater than the generator’s wattage
capacity.
5.4.2.2. The rated wattage of lights can be taken from light bulbs. The rated
wattage of tools, appliances and motors can usually be found on a data
label or decal affixed to the devices. If the appliance, tool or motor does
not give wattage, multiply volts times ampere rating to determine watts
(volts × amps = watts).
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5.4.2.3. Some electrical induction motors, require about three times more power
for starting than for running. This surge of power only lasts a few seconds
when starting. You MUST make sure you allow for high starting wattage
when selecting electrical devices to connect to the generator;
5.4.2.3.1.
5.4.2.3.2. Calculate the watts needed to start the largest motor.
Add to that figure the running watts ofall other connected
loads. Start the largest motor first and only one motor at a time.
5.5. Stopping the engine.
5.5.1. Switch off all loads then unplug them from the generator outlet sockets.
NEVER start orstop the engine with electrical devices plugged in and
turned on. Switch the main breaker down (OFF).
5.5.2. Let the engine run with no-load for several minutes to stabilise the internal
temperatures of engine and generator.
5.5.3. Move the engine switch to the OFF position,
5.5.4. Close the fuel valve.
5.6. Low oil level system shutdown.
5.6.1. The engine is equipped with a low oil level sensor that shuts down the engine
automatically when the oil level drops below a specified level.
5.6.2. If the engine shuts down by itself and the fuel tank has enough petrol, check
the engine oil level. Engine oil level should be checked daily.
5.7. High altitude.
5.7.1. To remain emissions compliant at high altitude (altitudes over 5,000 feet or
1524 meters) adjustment is required. This adjustment will cause decreased
performance, increased fuel consumption, and increased emissions. Contact
your dealer for high altitude adjustment information.
5.7.2. Operation of the engine at altitudes below 2,500 feet or 762 meters with the
high altitude kit is not recommended.
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6. MAINTENANCE
6.1. Follow the maintenance intervals shown below. More frequent service is required
when operating in adverse conditions.
MAINTENANCE SCHEDULE
After first 10hours Change the engine oil - use SAE15W40
Every 8 hours orDaily Clean the machine
Check the engine oil level
Every 25 hours or Yearly Clean the engine air filter
Every 100hours oRYearly
Yearly
Replace the engine air filter
Service the fuel valve
Service the spark plug
Check the muffler and the spark arrester
Clean the cooling system
6.2. General recommendations.
6.2.1. The warranty of the generator does not cover items that have been subjected to
operator abuse or negligence. To receive full value from the warranty, the
operator must maintain the generator as instructed in this manual. Some
adjustments will need to be made periodically to properly maintain the generator.
6.2.2. All adjustments in the Maintenance section of this manual should be made at
least once each season. Follow the requirements inthe “Maintenance Schedule”.
IMPORTANT Once ayear replace the spark plug and the air filter. A new spark plug and a clean
air filter helps the engine runbetter and last longer.
6.2.3. Generator maintenance.
6.2.3.1. Generator maintenance consists of keeping the unit clean and dry. Operate
and store the unit in a clean dry environment where it will not be exposed to
excessive dust, dirt, moisture or any corrosive vapors. Cooling air slots in the
generator must not become clogged with snow, leaves, or any other foreign
material. DO NOT use the machine where it can become exposed to rain,
snow, sleet or any other type of moisture.
6.2.3.2. Check the cleanliness of the generator frequently and clean when dust, dirt,
oil, moisture or other foreign substances are visible on its exterior surface.
Never insert a finger, object ortool through the air cooling slots, even ifthe engine isnot running.
DO NOT use a garden hose or pressure washer to clean the generator. Water can enter the
engine fuel system and cause problems. In addition, if water enters the generator though
Change the engine oil - use SAE15W40
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the cooling air slots, some water will beretained invoids and crevices of the rotor and stator
winding insulation which can cause electrical shorts circuits and damage the alternator. Water
and dirt build up onthe generator internal windings will eventually decrease the insulation
resistance ofthese windings.
6.2.4. Cleaning the external of the generator.
6.2.4.1. Use a damp cloth towipe the exterior surfaces.
6.2.4.2. A soft, bristle brush may be used to remove dirt, oil etc.
6.2.4.3. A vacuum cleaner may be used to pick up loose dirt and debris.
6.2.4.4. Low pressure air (not to exceed 25 psi) may be used to blow away dirt.
6.2.4.5. Check cooling air slots and openings on the generator. These openings must
be kept clean and unobstructed.
6.3. Engine Maintenance.
When working onthe generator, you MUST always disconnect the spark plug HT cable from the
spark plug and keep the cable away from the spark plug. The fuel tap should also beinthe OFF
position.
6.4. Oil change.
Hot oil may cause burns. Allow engine to cool before draining oil. Avoid prolonged or repeated
skin exposure to used oil. Thoroughly wash exposed areas with soap.
6.4.1. Beforestarting youMUST allow the engine tocool down slightly.While the engine is
cooling down;
6.4.1.1. Clean area around oil drain plug.
6.4.1.2. Remove oil drain plug and dipstick from the engine to drain oil completely
into a suitable container.
6.4.1.3. When oil has completely drained, refit the oil drain plug and fully tighten.
6.4.1.4. Fill the engine with recommended oil. SA15W40
6.4.1.5. Wipe up any spilled oil.
6.4.1.6. Dispose of used oil ata proper collection center.
6.4.1.7. Refit the dipstick.
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6.4.2. Spark plug replacement.
6.4.2.1. Use spark plug F6TC, BPR4ES or Champion RN14YC. Replace the plug once
each year. This will help the engine to start easier and run better.
6.4.2.2. Stop the engine and remove the HT lead from the spark plug.
6.4.2.3. Clean the area around the spark plug and remove it from the cylinder head.
6.4.2.4. Set the spark plug’s gap to 0.70-0.80 mm (0.028-0.031 in.). Install the
correctly gapped spark plug into the cylinder head and torque to 15 ft/lbs.
6.4.3. Spark arrestor service. # Spark arrester fitment may vary model to model.
6.4.3.1. Shut off generator and allow the engine and muffler to cool down
completely before servicing spark arrestor (located on the back of the
muffler).
6.4.3.2. Remove the clamp and spark arrestor screen.
6.4.3.3. Clean the spark arrestor screen with a small wire brush.
6.4.3.4. Replace the spark arrestor if it is damaged.
6.4.3.5. Refit the spark arrestor.
6.4.4. Air filter service.
6.4.4.1. The engine will not run properly and may be damaged if using a dirty air
filter. Replace the air filter once a year. Clean or replace more often if
operating under dusty conditions.
6.4.4.2. Undo air filter cover screw and remove air filter cover.
6.4.4.3. Remove sponge filter element.
6.4.4.4. Wash filter element in soapy water. Squeeze filter dry in clean cloth (DO NOT
TWIST).
6.4.4.5. Clean air filter cover before re-installing it.
6.4.4.6. Put a drop of engine oil onto sponge filter element this will help avoid ice
blocking it during winter season.
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6.4.5. Valve clearances.
IMPORTANT If you are not competent to carry out this procedure or the proper tools are not
available. We advise that you take the generator to your dealer to have the valve clearance
adjusted. This is a very important step to ensure longest life for the engine.
6.4.5.1. After the first 50 hours of operation, check the valve clearance in the engine
and adjust if necessary.
6.4.6. General.
6.4.6.1. The generator should be started at least once every seven days and be
allowed to run for at least 30 minutes. If this cannot be done and the unit
must be stored for more than 30 days, use the following information as a
guide to prepare it for storage.
NEVER store engine with fuel in tank indoors or in enclosed, poorly ventilated areas where
fumes may reach an open flame, spark or pilot light as on a furnace, water heater, clothes dryer
or other gas appliance.
Drain the fuel into an approved container outdoors, away from open flame. Make sure that the
engine is cool. DO NOT smoke in the vicinity. NEVER cover the generator while the engine and
exhaust areasare HOT.
6.4.7. DO NOT store petrol from one season toanother.
6.4.8. Replace the petrol container if it starts to rust. Rust and/or dirt in the petrol
will cause problems with the carburetor and fuel system.
6.4.9. If possible, store the unit indoors and cover it to give it protection from dust
and dirt.
6.4.10. Make sure that you empty the fuel tank.
6.4.11. If it isnot practical toempty the fuel tank and the unit is to be stored forsome
time, use acommercially available fuel stabilizer added to the petrol to
increase the life of the petrol.
6.4.12. Cover theunit with a suitable protective cover that does not retain moisture.
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