HY3100LE / HY7000LE / HY9000LEk User Manual
Contents
1. Approximate Specific VDC 8 3 Amps Caution should be Charged Voltage Gravity exercised when charging batteries to ensure that the battery does not get overcharged 100 13 2 1 255 1 275 75 9 9 1 215 1 235 A CAUTION OG 50 6 6 1 180 1 200 3 2596 3 3 1 155 1 165 0 0 1 110 1 130 6 2 2 Charging instructions for the battery 6 2 3 Disconnect the battery leads 6 2 4 Open the battery filler caps 6 2 5 Checkthat the batteries are full to the upper limit 6 2 6 Only use distilled water to fill up battery 6 2 7 Measure the specific gravity SG of the battery fluid electrolyte and calculate the charging time in accordance with the table to the right 6 2 8 The specific gravity for a fully charged battery shall be between 1 255 and 1 275 You should check the SG every hour 6 2 9 If the battery requires charging connect the battery to the 12 V 8 33 Amp charging outlet Make sure you observe the correct polarity at the battery Red to positive and Black to negative Page 12 Rev 3 7 STOPPING THE ENGINE 7 1 Turn OFF and unplug all appliances attached to the machine 7 2 Turn the AC switch OFF 7 3 Turn the engine switch to the OFF position 7 4 Turn OFF the fuel tap 8 BATTERY 8 1 The battery isa 12 volt 14Ah 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 s2. HYUNDAI PETROL GENERATOR Models HY3100LE HY7000LEK HY9000LEKk User Manual Licensed by Hyundai Corporation Korea 10 11 12 13 14 15 CONTENTS Section Description SAFETY MACHINE LAYOUT PRE OPERATION CHECKS STARTING THE ENGINE RECOIL STARTING THE ENGINE USING IGNTION KEY USING THE MACHINE STOPPING THE ENGINE BATTERY PERIODIC MAINTENANCE TROUBLESHOOTING STORAGE SPECICIFATIONS WIRING DIAGRAM CONTACT DETAILS DECLARATIONS of CONFORMITY Page 2 Page N N S 10 11 11 12 13 13 14 16 19 20 20 21 22 23 24 Rev 3 1 SAFETY A 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 Personal Protective Equipment PPE CLOTHING Ku BE WORN FEN BE WORN W DANGER WARNING A CAUTION
3. DANGER indicates a WARNING indicates a CAUTION hazard which if not indicates a NOTE indicates a hazard which if not situation that could avoided might result easily result in gt serious injury or death minor or moderate equipment damage READ MANUAL injury EXPLOSION ELECTRIC SHOCK KICKBACK HOT SURFACE TOXIC FUMES SLIPPERY MOVING PARTS hazard which if not avoided could resultin avoided could result in serious injury or death 1 3 Carbon Monoxide 1 3 1 Carbon monoxide is a 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 Page 3 Rev 3 1 3 2 1 Headaches dizziness nausea breathlessness collapsing or loss of consciousness 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
4. 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 oil falls below the lower level the 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 Theengine starter switch controls the ignition 1 5 3 2 Inthe OFF Position the ignition circuit is switched off and the engine will not run 1 5 3 3 In the position the engine is ready for starting 1 5 3 4 In the START position pushed against spring tension the starter motor turns and the machine will start 1 5 4 ACSwitch 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 ACswitch turns OFF then before resetting reduce load and keep below the rated output of the machine 1 5 5 DO NOT Connect to any AC outlets commonly known as back feeding it is extremely dangerous Page 6 Rev 3 2 MACHINE LAYOUT Fuel Tank HT Lead amp Spark Plug HY7 ODOLE p Oil Filler Plug Page 7 Rev 3 Starter 5witch EU 4 Function Display 12 VDC 3 Amp Outlet Ns Main Earth Point AC Outlets Only 1 x 110 socket on HY3100 Page 8 Rev 3 3 PRE OPERATION CHECKS A CAUTION Pre operation
5. 0 x 460 720 x 530 x 550 Net Weight 48Kg 85Kg 99Kg Gross Weight 50Kg 90Kg 104Kg c Page 21 Rev 3 13 WIRING DIAGRAMS N B Subject to change without prior notice 13 1 ELS NOLIV IHv A uh yu qaa pw Ske ord shm ur mase nemne ME aufus auos 391205 Ante VIL ASI YA ASU VIE Rev 3 Page 22 14 GENPOWER CONTACT DETAILS Postal address Genpower Limited Isaac Way Pembroke Dock Pembrokeshire SA72 4ARW UK Telephone contact number Office 44 0 1646 687880 Email contact service genpower co uk Web site www hyundaipowerequipment co uk Page 23 Rev 3 15 DECLARATIONS OF CONFORMITY 15 1 Genpower Ltd confirms that these Hyundai products conform to the following CE Directives 15 1 1 2006 42 EC Machinery Directive 15 1 2 2004 108 EC EMC Directive 15 1 3 2000 14 EC Noise Emissions Directive 15 1 4 97 68 EC NRMM Emissions Directive 15 1 5 2006 95 EC Low Voltage Directive Page 24 Rev 3 Page 25 Rev 3 Page 26 Rev 3 Page 27 Rev 3 HYUNDAI GENPOWER LTD Isaac Way London Road Pembroke Dock UNITED KINGDOM SA72 4RW T 44 0 1646 687 880 44 0 1646 686 198 E info hyundaipowerequipment co uk
6. aler Locate and tighten Internal generator problem Contact dealer Engine RPM set too HIGH or too Output power available LOW machine running erratically 11 A CAUTION 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 With ignition switch OFF use the recoil starter to turn the engine over several times 11 2 3 Replace spark plug and pull recoil until you feel compression stop pulling at this stage 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 Page 20 Rev 3 12 SPECIFICATIONS 8 3Kva 9 1Kva 7 3Kva 8 0Kva 1C425 E Air cooled 4 cycle OHV Petrol Engine 68 x 54 88 x 64 90 x 64 425cc 16HP 4000RPM Continuous Lubricating Oil 15w40 Lubricating Oil Capacity 0 6 Litre Starting System Recoil and Electric Ignition System Spark Plug Type BPR 5ES or BPR 6ES Net Dimension L x W x H 545 x 425 x 440 699 x 510 x 532 Overall Dimension L x W x H 560 x 44
7. 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 Fueltank capacities Modelfs J Ful gt 12 Litres 22 Litres WARNING 3 1 5 DO NOT refill tank while engine is running or HOT 3 1 6 Close fuel tap before re fuelling Fuel Tap Recoil Starter 3 1 7 DO NOT allow any dust dirt water or any other foreign objects get into the fuel or fuel tank 3 1 8 Wipe off any spilt fuel thoroughly before starting the engine 3 1 9 Keep all sources of ignition and naked flames away from the area in which you are fueling 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 oil filler cap and check engine oil level 3 2 3 If oil level is below the lower level line refill with oil 15W 40 oil to the upper level N B do not screw filler in the oil filler cap when checking oil level 3 2 4 Change contaminated oil 3 2 5 Oil Capacities Page 9 Rev 3 Model s Full gt HY3100LE HY7000LEK HY9000LEKk 3 3 Earthing Ground 3 3 1 Always earth the generator STARTING THE ENGINE RECOIL NOTE before starting the engine e Turn OFF the AC switch DO NOT connect any electrical appliances to th
8. e machine 4 1 Turn the fuel tap to ON position 4 2 Turn the engine switch to ON 4 3 Turn the choke lever to the Choke position Not necessary when engine is warm RUN Position CHOKE Position 4 4 Pull the starter handle slowly until resistance is felt This is the Compression point Return the handle to its original position and pull swiftly Do not fully pull out the rope After starting allow the starter handle to return to its original position while still holding the handle 4 5 Warm up the engine 4 6 Turn choke lever back to the RUN position 4 7 Continue to warm engine for a few minutes without load Page 10 Rev 3 5 STARTING THE ENGINE USING IGNITION KEY NOTE before starting the engine e 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 ON 5 3 Slide the choke lever to the Choke position Not necessary when engine is warm RUN Position CHOKE Position 5 4 Insert key and turn to start position this will against spring tension for approximately 10 seconds 5 5 Once the machine starts to run release the key 5 6 If machine does not start after first attempt wait for 60 seconds and attempt a restart 5 7 Warm up the engine 5 8 Slide choke lever back to the RUN position 5 9 Continue to warm engine for a few minute without load 6 USING MACHINE 6 1 Usi
9. ead bolt bolts properly Replace D d gasket amaged gaske gasket Pull recoil starting rope faster Debris in fuel tank Clean tank Clear blockage emt Fill with No Fuel Poor fuel fresh fuel Engine will Open fuel not start Fuel valve not Open valve Or Sparkplug Clean spark dirty plug Insufficient compression Insufficient pulling speed on recoil starting No fuel to combustion Blocked fuel line No or poor Damaged Replace rk spark plu spark plu output spa park plug park plug Or magneto Sufficient Combustion Improperly Consult chamber has dealer compression fuel adjusted carburettor Correct Insufficient spark pulling Pull recoil speed on starting recoil rope faster starting Engine runs erratically Check and Incorrect fuel replace fuel as required Check and loading Check and Overheating POS cooling system 10 2 Generator Troubleshooting N B all corrective actions should be carried out by suitably qualified person s Page 19 Rev 3 Possible cause s Corrective action s Circuit breaker tripped Reset breaker Poor connections or broken Indicator light ON no AC output wire s Check and repair Contact dealer Reset breaker Poor connections or faulty DC Check and repair Indicator light OFF no DC output I power wires Generator problem Contact dealer With NO LOAD for 60 hertz set at 3780 RPM With NO LOAD for 50 hertz set at 3150 RPM Otherwise Contact de
10. hort circuiting 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 Page 13 Rev 3 9 PERIODIC MAINTENANCE 9 1 Maintenance chart Initial and 1 Every 3 Every 6 Every 10 Months Months Months or 50 or 100 or 300 Hours Hours Hours Month or 20 Hours Check condition adjust gap and clean as necessary Engine Oil Check Oil level Replace Air Filter Clean and replace if necessary Fuel Filter Check filter replace as necessary Check and adjust Valve clearance when engine is cold Check fuel hose for cracks and damage Replace when necessary Spark Plug Fuel Line Check for leaks re tighten or replace gasket as required Check silencer screen clean and replace as required Check Choke Carburetor operation Check Cooling fan Cooli t Check recoil starter operation De carbonising As necessary Asnecessa Check all fittings and All fitting and fasteners If missing Exhaust system Starting system fasteners or loose replace and tighten Page 14 Rev 3 9 2 Engine Oil replacemen
11. lencer screen Clean the carbon deposits out of the silencer screen using a wire brush Check the silencer screen Replace it if damaged Install the silencer screen and silencer protector Page 17 Rev 3 remove cover undo these four balts Clean residual carbon exhaust deposits from exhaust outlet 9 8 Carburettor maintenance 9 8 1 Turn fuel tap to OFF position 9 8 2 Remove the Fuel Shut Off solenoid by undoing the two retaining screws 9 8 3 Remove the float bowl retaining bolt 9 8 4 Remove bowl and make sure seal is in good condition replace as required 9 8 5 Using a flat bladed screwdriver unscrew the main jet and remove the emulsion tube N B Take care not to drop these 9 8 6 Blow out main jet and emulsion tube with a low pressure airline Also blow out the hole where these were removed from 9 8 7 Re assembly is the reverse of the above 9 8 8 If the machine is left for more than a month drain the petrol from the carburettor by either running the machine dry of petrol or releasing the petrol by loosening the flat bowl drain screw N B Petrol tends to become wax like over time Fuel Shut Off Solenoid Page 18 Rev 3 10 TROUBLESHOOTING 10 1 Engine Troubleshooting N B all corrective actions should be carried out by suitably qualified person s n Corrective Condition Possible cause s action s Loose spark Plug memen pile properly Tighten Loose cylinder h
12. let them know that you suspect carbon monoxide poisoning 1 3 5 DO NOT use in an enclosed area or a moving vehicle DANGER ap BREATHING IN CARBON MONOXIDE y FUMES CAN KILL YOU To help protect against CO poisoning install a Carbon Monoxide detector a TR R asss mid EVAN Soy To NEVER use Petrol Diesel powered equipment inside especially a home garage tent camper van caravan motorhome or boat EVEN if doors windows vents and hatches are open Only use OUTDOORS far away from doors windows vents and open hatches as possible to b prevent inhaling fumes READING MANUAL BEFORE USE WILL HELP AVOID OTHER MACHINE HAZARDS 1 4 General fuel safety 1 4 1 Fuel Safety additional information can be obtained from the Health and Safety Executive HSE document SR16 N CAUTION 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 vinn 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 f
13. ll it securely Page 15 Rev 3 Filter Cover Primary filter 9 4 Spark Plug 9 4 1 Use spark plug BPR5ES or BPR6ES 9 4 2 The spark plug electrode should be a Tan colour 9 4 3 Spark plug gap should be 0 7mm to 0 8mm 0 028 to 0 031 WARNING On completion of this operation you MUST make sure that the fuel tap Cock cup is tightened securely Page 16 Rev 3 9 5 Fuel Tap Cock 9 5 1 9 5 2 Stop the engine Empty fuel tank and make sure fuel tap is higher than the fuel inside the tank 9 9 3 9 5 4 9 9 9 9 5 6 9 5 7 N NOTE Turn the fuel tap cock lever to OFF Clean with solvent Wipe off Check filter clean as required Check the gasket Replace it if damaged Fuel tap shown in ON position 9 6 Fuel Tank Filter WARNING On completion make sure fuel filler cap is secured tightly 9 6 1 9 6 2 9 6 3 9 6 4 Remove filler cap Remove fuel filter and clean with solvent Wipe off and dry with a clean lint free rag Replace filter into fuel tank 9 7 Silencer Cover LN WARNING The engine and silencer will become very hot after the engine has been run Avoid touching the engine and silencer while they are still hot with any part of your body or clothing during inspection or repair 9 7 1 SNA 9 7 3 9 7 4 Make sure silencer and exhaust are cold before continuing this work Remove the silencer protector and si
14. ng AC output CAUTION Make sure the electrical apparatus to be powered is turned OFF before plugging into socket outlet Make sure that you do not exceed the rated load of the machine o Toincrease the life span of the generator it is recommended that you do not consistently load the machine and ideally use it at 7596 of machines rated capacity Make sure that the load current is within the rated current of the outlet socket e DONOT change voltage changeover switch whilst engine is running DO NOT connect any electrical appliances to the machine Page 11 Rev 3 Voltage mode Frequency mode 6 1 1 Select required output voltage 6 1 2 Check the output on the Digital Voltmeter is reading the correct voltage 6 1 2 1 Display will read output voltage depending Hvunoa on the selection either 115 VAC or 230 VAC Event Timer Mode 6 1 3 The Digital panel only becomes active when the Main MCB is in the ON position The following will be displayed by successive presses of the M or mode button cO Light will reset to zero when main MCB is turned OFF Total Run time ent Timer or current running time Hours This 6 1 4 Turn the main AC switch to the OFF position 6 1 5 Insert the plug into the outlet you are about to use 6 1 6 Turn the main AC switch to the ON position and turn the electrical appliance ON 6 2 Using DC outlet 6 2 1 The DC outlet is an unregulated 12
15. ollows but are not limited too Hand protection 1 4 8 3 Page 4 Rev 3 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 SS 1 4 9 1 Always fuel and defuel 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
16. t N CAUTION After engine has been run prior to changing the oil will be very hot Wear correct PPE minimum of gloves and overalls A CAUTION DO NOT allow any dust dirt or any other debris enter oil or crankcase 9 2 1 Place the machine on a level surface and warm up the engine for several minutes Then stop the engine 9 2 2 Remove the oil filler cap 9 2 3 Place an oil pan under the engine Remove the oil drain plug so that the oil lt MI Oil Filler cap can be completely drained ER Nie 9 2 4 Check the oil drain plug gasket oil 87 filler cap and O ring If damaged al replace 9 2 5 Reinstall the oil drain plug 9 2 6 Addengine oil to the upper level recommended oil 15W 40 oil Oil Dipstick Upper Level 9 3 Air filter AN CAUTION The engine should not be run without the filter element piston and or cylinder wear can occur 9 3 1 Maintaining the air filter in good condition is very important Dirt induced through improperly installed improperly serviced or inadequate elements damages and wears out engines ALWAYS Keep the element always clean 9 3 2 Remove air filter cover 9 3 3 Take out the air filters elements wash in soapy water rinse in fresh water and alow to dry it 9 3 4 Put clean engine oil on to foam air filter element squeeze out excess oil by hand 9 3 5 Lastly put the filter element back into the filter housing and insta
17. 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 Page 5 Rev 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
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