Hyundai DHY2500L/E, DHY4000L/E, DHY6000L/E, DHY6000L/E-3, DHY4000SE/3 User Manual

MADE UNDER LICENSE OF HYUNDAI CORP. SEOUL, KOREA

OPEN TYPE-DHY2500L/E DHY4000L/E DHY6000L/E/3

SILENT TYPE-DHY4000SE/3 DHY6000SE/3

WELDER TYPE-DHYW180AC DHYW190AC

DIESEL GENERATOR

USER MANUAL

REVIEW MANUAL CAREFULLY TO AVOID PERSONAL INJURY

EN

PREFACE

Thank you for purchasing HYUNDAI diesel generator.

This operation manual will tell you how to operate and service your HYUNDAI diesel gene-

rator set propertly.

Please read this manual before using the generator set to ensure the proper operation.
Follow the instructions to keep your generating set in in the best working conditions and
extend the life of it. If any comments or problem please contact the place where you bought
the generator set or also can contact the manufacturer directly (check contact formular in
last page).

It is also strong recommend that you send the receipt form to the manufactures in order
to register your product for future problems or complains.

All information in this publication is based on the latest product information available at
the time of printing. ITC Power Co.ltd., reserves the right to make changes at any time
without notice and without incurring any obligation. No part of this publication may be repro­duced without written permission.

This manual deals with the general items for the HYUNDAI diesel generator set, however
this manual may vary with the development of the product in the future.

This manual should be considered a permanent part of the generator and should remain
with the generator if resold.

Please give special attention to the warnings and cautions. A safety message alerts you
to potential hazards that could hurt you or others. Each safety message is preceded by a
safety alert symbol and one of three words, DANGER, WARNING, or CAUTION.

These signal words mean:

You CAN be HURT if you don’t follow instructions.

You CAN be KILLED or SERIOUSLY HURT if you don’t follow
instructions.

You CAN be HURT if you don’t follow instructions. Also the machi­ ne can be damage

Non respect the instructions explained in this user manual will avoid the guarantee of the
generator set.

Contact Group ITC Power staff for any clarification about the use of the generator here
explained. Contact details in the last page.

! DANGER

!

WARNING

!

CAUTION

1

SAFETY INFORMATION

In order to ensure a safety use of the generator please follow the next safety
instructions:

1. Check the outside of the generator in order to detect any apparent trouble.

2. The use or good quality oil and diesel is a must.

3. Storage should be in a dry place. Frost damage permanently your group.

Drain your machine completely before storing in a dry hot place.

4. Check and clean filters regularly.

5. Make sure all subset of the machine are right.

6. Exhaust fumes contain carbon monoxide, a very dangerous gas, colorless

and odorless, never use the generator in premises or areas closed. Make
sure the group is installed in a location with adequate ventilation or equipped
with a smoke extractor.

7. The exhaust temperature rises during the use of the group and still burning

even after shutdown. Take care never to touch or move it to store before
being on it is cool enough.

8. Repair your generator shall be made by a qualified person and trained for this

purpose.

9. Do not smoke, do not flame or spark when operating or filling the tank, store

the generator near flammable materials.

10. Store the group in a well ventilated area.

11. Never transport or store your generator in a horizontal or leaning of fuel leak

and / or oil or will permanently damage your machine.

12. Never stop the generator when is load applied, be sure to disconnect any

apparatus from the generating set prior start of prior stop.

13. Do not allow children to operate the engine. Keep children and pets away

from the area of operation.

14. The engine and exhaust become very hot during operation. Keep the gene-

rating set at least 1.5 meter away from buildings and other equipment during
operation. Keep flammable materials away, and do not place anything on the
engine while it is running.

15. Gasoline is highly flammable and explosive. Turn engine off and let cool

before refueling.

16. To avoid electric shocks or short circuit, do not touch the generating set

when your hands are wet. This generating set is not water proof, so it should
not be used in a place exposed to rain, snow or water spray. Use of the
generating set in a wet place can cause short circuits and electric shock
during operation.

17. The generating set must be grounded to prevent electrical shocks from from

faulty appliances. Please connea lenght of heavy wires between the genera­ting set ground terminal and a external ground source

18. Most applicance motors requiere more than their rated waltage for star-up,

so follow recommendations of your dealer to choose the right power for your
applicance.

19. Do not exceed the expecific current limit of any socket.

20. Do not connect directly the generating set to a household circuit.

18. No guarantee will be covered in case of non-compliance of start-up procedu-

res and safety precautions.

2

CONTENTS

1. MAIN TECHNICAL SPECIFICATIONS & DATA

1.1 Main technical specifications and data open type

1.2 Main technical specifications and data soundproof type

1.3 Main technical specifications and data welder type

1.4 Basic parameters

1.4.1 Provide of rated power under following conditions

1.4.2 Working reliable under the following conditions

1.4.3 Working reliable under special conditions

1.4.4 Selection of the right power for the generator

1.5 Name identification and name plate

2. IDENTIFICATION OF THE PARTS

2.1 Control panel LED3

2.2 Control panel LED4

2.3 Control panel LED4 Welder Type

2.3 Identification of the parts soundproof type

2.4 Identification of the parts open type

3. OPERATION OF DIESEL GENERATING SET

3.1 Notes of operating diesel generating set

3.1.1 Preventing of fire

3.1.2 Preventing the suction of exhaust gas

3.1.3 Preventing the damage by high-temperature parts

3.1.4 Preventing the electric shock or short circuit

3.1.5 Other safety points

3.1.6 Charging the battery

3.2 Preparation before starting

3.2.1 Selection of the fuel

3.2.2 Filling in lube oil

3.2.3 Check air cleaner

3.2.4 Checking the generator load

3.2.5 Checking fuel piping

3.3 Checking & operating the engine

3.3.1 Checking lube oil level

3.3.2 Operation in trial

3.4 Starting & operating the generator

3.4.1 Preparation before starting

3.4.2 Starting

3.4.3 Make the inspection during the operation.

3.5 Adding load

3.6 Stop the generator

5

5

6

7

8

8

8

8

9

9

10

10

11

12

13

14

15

15

15

15

15

15

15

15

16

16

16

17

18

18

18

18

18

19

19

19

20

21

21

3

CONTENTS

3.7 Battery

3.8 Control panel

3.9 Welding process

4. MAINTENANCE OF DIESEL GENERATING SET

4.1 Maintenance of diesel generator

4.1.1 Change lube oil

4.1.2 Change/clean the element of air cleaner

4.1.3 Change fuel filter

4.1.4 Check the electrolytic and charge the battery

4.1.5 General maintenance

5. LONG TERM STORAGE

6. TROUBLE SHOOTING AND REMEDY

7. GUARANTEE

8. NOTES

4

22

22

22

23

23

23

24

26

27

27

28

28

29

30

1.1 Main technical specifications and data open type

1.

MAIN TECHNICAL SPECIFICATIONS & DATA

30mA BREAKER

AC230V

AC230V

DIGITAL PANEL

+

-

STARTER SW

ONOFF

START

PRE.
HEATER

DC 12V 8.3Amp

FUSE

DC12V 10Amp

FUSE

L

W

H

DHY2500L 610 460 530 630 480 565 Carton

DHY4000L/E 680 460 560 710 480 600 Carton

DHY6000L/E 720 480 600 740 500 645 Carton

DHY6000L/E-3 720 480 600 740 500 645 Carton

Width Height

Model

Length Width HeightLength

Product Size (mm)

Packaging Size (mm)

Package
Material

50 / 60
2 / 2.2 kW

2.2 / 2.4 kW
230 / 120-240

9.6 / 22
2x16A / XX
LED4
14
30 / 27

76.9 / 77.2
12 / 8.3
17

Diesel
D200

4.2
Manual / Elec. start
211

0.75

A2-1 / A2.2-1
2 / 2.2
1
AVR

55/66
58/69
164/340/340

50 / 60
3 / 3.3 kW

3.3 / 3.6 kW
230 / 120-240

14.3 / 30
2x16A / XX
LED4
14
21 / 19

77.1 / 77.4
12 / 8.3
17

Diesel
D300
6
Manual / Elec. start
296

1.1

A3-1 / A3.3-1
3 / 3.3
1
AVR

68/79
72/83
108/222/293

50 / 60
5 / 5.5 kW

5.5 / 6.0 kW
230 / 120-240

23.9 / 50
2x16A / XX
LED4
14
13 / 11.5

77.5 / 78
12 / 8.3
36

Diesel
D400
10
Manual / Elec. start
418

1.65

A5-1 / A5.5-1
5 / 5.5
1
AVR

93/108
98/113
102/213/281

50 / 60

6.3 / 6.9 kVA

6.9 / 7.6kVA
400 / 120-240

16.2 / 36
1x 16A/3~ & 1x 16A/1~/ XX

(1)

LED4
14
13

77.5 / 78
12 / 8.3
36

Diesel
D400
10
Manual / Elec. start
418

1.65

A5-3 / A5.5-3

6.3 / 6.9

0.8
AVR

93/108
98/113
102/213/281

Generator SetEngine

Alternator

Log.data

Frequency (Hz)
Rated Power
Max.Power
Voltage (V)
Current (A)
Sockets
Display
Fuel Tank Capacity (L)
Running Time under 50% Load (hr.)
Noise Level behind 7 Meters 50% Load (dBA)
DC Output (V/A)

(2)

Battery (Ah)

Engine Type
Engine
Power Output (HP)
Start Method
Displacement (ml)
Oil Capacity (L)

Alternator
Rated Power (kVA)
Power Factor (Cosφ)
Voltage Regulation

N.G.(kg)
G.W.(kg)
Loading capacity 20/40/40HQ

Generator Model DHY2500L/E DHY4000L/E DHY6000L/E DHY6000L/E-3

(1) Single phase socket thermal protected
(2) 100W max. output. 10A fuse protection

Values might vary without prior notice, for updated information please visit our web page

5

1.2 Main technical specifications and data soundproof type

1.

MAIN TECHNICAL SPECIFICATIONS & DATA

(1) Single phase socket thermal protected
(2) 100W max. output. 10A fuse protection

Values might vary without prior notice, for updated information please visit our web page

Width Height

Model

Length Width heightLength

Product Size (mm)

Packaging Size (mm)

Package
Material

INTELLIGENT CONTROLLER

+

-

ONOFF

START

STARTER SW EMERGENCY STOP

PRE.
HEATER

ATS

AC230VAC230V

30mA BREAKER

DC 12V 8.3Amp

FUSE

DHY4000SE 920 520 760 950 570 790 Carton

DHY6000SE 920 520 760 950 570 790 Carton

DHY6000SE-3 920 520 760 950 570 790 Carton

H

L

W

Generator Model DHY4000SE DHY6000SE DHY6000SE-3

Generator SetEngine

Alternator

Frequency (Hz)
Rated Power
Max.Power
Voltage (V)
Current (A)
Sockets
Display
Fuel Tank Capacity (L)
Running Time under 50% Load (hr.)
Noise Level behind 7 Meters 50% Load (dBA)
DC Output (V/A)

(2)

Battery (Ah)

Engine Type
Engine
Power Output (HP)
Start Method
Displacement (ml)
Oil Capacity (L)

Alternator
Rated Power (kVA)
Power Factor (Cosφ)
Voltage Regulation

N.G.(kg)
G.W.(kg)
Loading capacity 20/40/40HQ

50 / 60

6.3 / 6.9 kVA

6.9 / 7.6 kVA
400 / 120,240

16.2 / 36
1x 16A/3~ & 1x 16A /1~ / XX

(1)

LED4
17
16 / 14.5

72.6 / 72.8
12 / 8.3
36

Diesel
D400E
10
Elec. start
418

1.65

A5-3S / A5.5-3S

6.3 / 6.9

0.8
AVR

160
167
68/144/144

50 / 60
5 / 5.5 kW

5.5 / 6.0 kW
230 / 120,240

23.9 / 50
2x16A / XX
LED4
17
16 / 14.5

72.6 / 72.8
12 / 8.3
36

Diesel
D400E
10
Elec. start
418

1.65

A5-1S / A5.5-1S
5 / 5.5
1
AVR

160
167
68/144/144

Log.data

50 / 60
3 / 3.3 kW

3.3 / 3.6 kW
230 / 120,240

14.3 / 30
2X16A / XX
LED4
17
23 / 21
72 / 72.1
12 / 8.3
17

Diesel
D300E
6
Elec. star
296

1.1

A3-1S / A3.3-1S
3 / 3.3
1
AVR

150
157
68/144/144

6

Generator SetEngine

Alternator

D-diesel engine AC-welder set

Specifications are subject to continuous product delevopment

width height

Model

thgiehhtdiwhtgneLLength

Product Size (mm)

Packaging Size (mm)

Package
Material

Frequency (Hz)
Rated Power
Max.Power
Voltage (V)
Rated welding current (A)
Rated welding voltage (V)
Display
Fuel Tank Capacity (L)
Running Time under 50% Load (hr.)
Noise Level behind 7 Meters (dBA)
DC Output (V/A)

(2)

Battery (Ah)

Engine Type
Engine
Power Output (HP)
Start Mothod
Displacement (ml)
Oil Capacity (L)

Alternator
Rated Power (kVA)
Power Factor (Cosφ)
Voltage Regulation

N.W.(kg)
G.W.(kg)
Loading capacity 20/40/40HQ

Generator Model DHYW180AC DHYW190AC

DHYW180AC 720 530 580 740 550 610 Carton

DHYW190AC 720 530 580 740 550 610 Carton

50

4.5 kW
5 kW
230
12
180
LED4
14
30

77.5
12 / 8.3
36

Diesel
D400
10
Electrical start
418

1.65

A5W

2.5
1
AVR

110
113
102/213/281

50

2.5 kW

(1)

2.8 kW
230
12
190
LED4
14
30

77.5
12 / 8.3
36

Diesel
D400
10
Electrical start
418

1.65

A5W190

2.5
1
AVR

112
115
102/213/281

30mA BREAKER

AC230V

AC230V

DIGITAL PANEL

+

-

STARTER SW

ONOFF

START

PRE.
HEATER

DC 12V 8.3Amp

FUSE

DC12V 10Amp

FUSE

L

W

H

Log.data

(1) Can not use welding and power generation at the same time
Designed for professional use in welding
(2) 100W max. output. 10A fuse protection

1.3 Main technical specifications and data welder type

1.

MAIN TECHNICAL SPECIFICATIONS & DATA

7

1.4 Basic parameters

1. MAIN TECHNICAL SPECIFICATIONS & DATA

1.4.1 Provide of rated power under following conditions

table 1

1.4.2 Working reliable under the following conditions

table 2

1.4.3 Working reliable under special conditions

For special conditions appliances the power of the generator must be

correct according the bellow formala and table:

Ph = Pn x K1 x K2

Where:

Ph = Power on the requiered height

Pn = Nominal Power

K1 = 1 for use less than 12hr. Day / 0.9 for use over 12hr. Day

K2 = Coeficient according below table

table 3

Sea level (M） Ambient temperature（°C） Relative humidity
0 20 60%

Sea level (M） Ambient temperature（°C） Relative humidity
<1000 5-40 <90%

0 5 10 15 20 25 30 35 40 45

0

- - - - 1 0.98 0.96 0.94 0.92 0.89

200

- - - 0.99 0.97 0.95 0.93 0.92 0.89 0.86

400

- 1 0.98 0.96 0.94 0. 92 0.9 0.89 0. 87 0.84

600

1 0. 87 0.95 0.94 0.92 0.9 0.88 0. 86 0. 84 0.82

800

0.97 0.94 0. 93 0. 91 0.89 0.87 0. 85 0. 84 0.82 0.79

1000

0.94 0.92 0.9 0.89 0.87 0.85 0.83 0.81 0.79 0.77

1500

0.87 0.85 0. 83 0. 82 0.8 0.79 0.77 0. 75 0. 73 0.71

2000

0.81 0.79 0. 77 0. 76 0.74 0.73 0. 71 0. 7 0.68 0.65

2500

0.75 0.74 0. 72 0. 71 0.69 0.67 0. 65 0. 64 0.62 0.6

3000

0.69 0.68 0. 66 0. 65 0.63 0.62 0. 61 0. 59 0.57 0.55

3500

0.64 0.63 0.61 0.6 0.58 0.57 0.55 0.54 0.52 0.5

4000

0.59 0.58 0. 56 0. 55 0.53 0.52 0.5 0. 49 0. 47 0.46

HEIGHT (m.)

TEMPERATURE (Celsius)

HUMIDITY BETWEEN 0-50%

K2

0 5 10 15 20 25 30 35 40 45

0

1 1 1 1 0. 99 0.96 0.94 0.91 0. 88 0.84

200

1 1 1 0.98 0.96 0.93 0.91 0.88 0.85 0.82

400

1 0. 99 0.97 0. 95 0. 93 0.9 0. 88 0.85 0.82 0.79

600

0.99 0.97 0. 95 0.93 0.91 0. 88 0.86 0.85 0.8 0.77

800

0.96 0.94 0. 92 0. 9 0. 88 0.85 0.83 0.8 0. 77 0. 74

1000

0.93 0.91 0. 89 0.87 0.85 0. 83 0.81 0.78 0.75 0. 72

1500

0.87 0.85 0. 83 0.81 0.79 0. 77 0.75 0.72 0.69 0. 66

2000

0.8 0.79 0.77 0.75 0.73 0.71 0.69 0.66 0.63 0.6

2500

0.74 0.73 0.71 0.7 0.68 0.65 0.63 0.61 0.58 0.55

3000

0.69 0.67 0. 65 0.64 0.62 0.6 0. 58 0.56 0.53 0.5

3500

0.63 0.62 0. 61 0.59 0.57 0. 55 0.53 0.51 0.48 0. 45

4000

0.58 0.57 0. 56 0.54 0.52 0.5 0. 48 0.46 0.44 0.41

TEMPERATURE (Celsius)

HEIGHT (m.)

HUMIDITY BETWEEN 50-100%

K2

8

1. MAIN TECHNICAL SPECIFICATIONS & DATA

1.4.4 Selection of the right power for the generator

To make the right selection of the generator power please note that many

equipments have what is called a pick intensity when start up the machine.
For that reason the nomimal power of the equipmet is not the same as the
nominal power requiered. Please refer to the table bellow for reference but
in any case if you have any doubt tyou can consult with your specialiced
partner dealer, or also can contact the manufacturer for any clarification.

table 4

Do not connect any equipment that exceed the values above

mentioned.

1.5 Name identification and name plate

table 5

All products manufactured from ITC Power under license of HYUNDAI

Corporation, include a name plate on the generator set in order to trace the
production time and the model.

DHY2500L/E
DHY4000L/E
DHY4000SE
DHY6000L/E/3
DHY6000SE/3

LOAD

MODEL

Home electric appliance,
incandescent lamp.

Projector, electric cooker,
T.V., bulb, microwave.
1760 W

2640 W

4400 W

Machine with rectifier type
motor

Drilling machine, grinding
machine

733 W

1100 W

1833 W

Machine with capacitance
starting type

Water pump, air compressor.

1100 W

1650 W

2750 W

!

CAUTION

Single phase

Three phase

Luxury frame Silent frame,Electric start

Power output code

Diesel generator

DHY 6000 LE -3

-3

LICENSED BY HYUNDAI CORPORATION, KOREA

IMPORTED BY:

80

50

MODEL / SERIAL

POWER

Rated-Max.

WEIGHT / DIM.
DATE

D. M. Y.

kW VOLTAGE V

kg. mm.

Fig.1 Name Plate

Soundproof type

Fig.2 Name Plate

Open type

9