Hyundai Hirepro HY220DC User manual

1

FOR YOUR SAFETY

You must read and understand this manual

before use.

Keep this manual for future reference.

2

CONTENTS

PAGE NO.S

1

SAFETY

3 - 7

2

PRE OPERATION CHECKS

8 - 9

3

PART LOCATIONS

10

4

FUEL & OIL

11 - 12

5

STARTING PROCEDURE

13

6

STOPPING PROCEDURE

14

7

USING THE MACHINE

14

8

MAINTENANCE

15 - 18

9

TROUBLESHOOTING

19

10

STORAGE

20

11

SPECIFICATION

21

12

DECLARATIONS OF CONFORMITY

22

13

CONTACT DETAILS

23

INDEX

3

1.1 General Safety Notes.

1.2 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.

1.3 Please note the following safety points.

1.4 The machine should never be left it in a condition which would allow an untrained or

unauthorised person/s to operate this machine.

1.5 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.

1.6 Some or all of the following - warning signs, symbols and/or PPE pictograms may

appear throughout this manual. You MUST adhere to their warnings. Failure to do

so may result in personal injury to yourself or those around you.

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.

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 and keep the manual safe and pass it on if the machine is loaned or sold to another user.

You MUST fully understand all instructions to ensure you use and operate the machine safely.

Appropriate Personal Protective Equipment (PPE), MUST be worn at all times when operating or

repairing the machine.

1. SAFETY

4

1.10 Carbon Monoxide (where applicable).

1.11 Carbon monoxide is a colourless and odourless gas. Inhaling this gas can cause

death as well as serious long term health problems such as brain damage.

1.12 The symptoms of carbon monoxide poisoning can include but are not limited to the

following;

Headaches, dizziness, nausea, breathlessness, collapsing or loss of consciousness.

1.13 Carbon monoxide poisoning symptoms are similar to flue, food poisoning, viral

infections and simply tiredness. It is quite common for people to mistake this very

dangerous poisoning for something else.

1.14 To avoid carbon monoxide poisoning DO NOT use Petrol/Diesel powered equipment

inside any of the following; Home, garage, tent, camper van, mobile home, caravan

or boat. This is not exhaustive and if you are in any doubt contact your dealer.

1.15 If you think you have or someone around you has been affected by carbon monoxide

poisoning;

1.16 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 emergency services.

1.17 Contact a Doctor immediately or go to Hospital – let them know that you suspect

carbon monoxide poisoning.

1.18 DO NOT use in an enclosed area or moving vehicle.

1.20 General Fuel Safety (where applicable).

CAUTION

ALL FUELS ARE FLAMABLE

1.21 Fire Hazard – keep fuel away from all sources of ignition for example heaters.

Lamps, sparks from grinding or welding.

1.22

DO NOT carry out hot work on tanks that have contained fuel.

1.23 ALWAYS keep the work area tidy.

1.24 ALWAYS clean up spills promptly using absorbent granules and a lidded bin.

1.25 ALWAYS dispose of waste fuels correctly.

5

1.30 Fueling/De-fueling (where applicable).

CAUTION

ALL FUELS ARE FLAMABLE

1.31 ALWAYS fuel and defuel in a well ventilated area outside of buildings.

1.32 ALWAYS wear correct, suitable and fit for purpose Personal Protective Equipment

(PPE), suggested items are but not limited to safety gloves, overalls.

1.33 When fueling/de-fueling ALWAYS avoid inhaling fumes.

1.34 When de-fueling ALWAYS use a proper fuel retriever.

1.35 ALWAYS carry fuel in the correct and clearly marked container.

1.40 Electrical Safety (where applicable).

1.41 Electricity can kill – NEVER work on LIVE/ENERGISED equipment.

1.42 Prior to carrying out any maintenance work you MUST identify electrical isolation

methods and isolate all electrical supplies.

1.43 Prior to use and with all electrical supplies isolated, you MUST check all electrical

cables, plugs and connectors for the following;

1.44 Are intact and have no signs of damage, to include but not limited to bare wires,

chaffing, cuts and loose wiring.

1.45 If there are any signs of damage, the damage item MUST be taken out of service

until the damage has been repaired by an electrically competent person.

1.46 All trailing cables should be routed so as not to cause any kind of trip hazard.

1.47 NEVER work on or near electricity with wet hands, wet clothing and wet gloves.

1.50 Batteries (where present).

1.51 Batteries present a risk if they become damaged by 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

a liquid or gel form.

1.52 Should you come in to contact with electrolyte you should;

1.53 Remove all clothing contaminated with electrolyte. If you cannot remove then

saturate them in water.

1.54 Get medical assistance as soon as possible. You must advise the medical staff of

the type of acid.

6

1.55 Lead/acid battery = dilute sulphuric acid.

1.56 Nickel/cadmium = potassium hydroxide alkali electrolyte.

1.57 Use fresh running water to wash off excess electrolyte, continue this until medical

assistance arrives. Make sure that you do not was the electrolyte to another part of

your body or face.

1.58 If electrolyte comes in to 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 your face or body.

1.59 Gasses from charging batteries are highly flammable and great care should be taken

to charge in well ventilated areas.

1.59.1 There is an explosion risk if the battery terminals are short circuited, when

connecting/disconnecting ALWAYS exercise great care so that the terminals or

battery leads are NOT allowed to touch and cause a spark. ALWAYS use suitable

insulated tools.

1.60 Vibrations (where applicable).

1.61 Prolonged use of hand held (operated) machines will cause the user to feel the

effects of/from vibrations. These vibrations can lead to white finger (Raynaud’s

phenomenon) or carpal tunnel syndrome. This condition reduces the ability of the

hand to feel and regulate temperature, causing numbness and heat sensations and

may cause never damage and circulatory tissue death.

1.62 Not all factors that lead to white finger disease are known, but cold weather, smoking

and other diseases that affect blood vessels and blood circulation as well as large

and long-lasting impact of shocks are considered factors in the formation of white

finger. Note the following to reduce the risk of white finger and carpal tunnel

syndrome;

1.63 Wear gloves and keep your hands warm.

1.64 Take regular breaks.

1.65 All of the above precautions may help reduce the risk of white finger disease but not

rule out the carpal tunnel syndrome. Long-term and regular users are therefore

recommended to observe the condition of your hands and fingers. Seek medical

attention immediately if any of the above symptoms should occur.

1.70 Noise (where applicable).

1.71 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 hearing ear protection because your ability to hear alarm

warnings will be reduced.

1.72 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.

1.73 See CERTIFICATE of CONFORMITY section for Outdoor Noise declaration of

conformity.

7

WARNING

This generator will produce carbon monoxide gas which if inhaled, can be fatal.

Only ever operate this machine outdoors and clear of any buildings.

1.80 The engine and exhaust will become very hot during and after use.

Care must be taken not to touch these parts.

1.81 Place the machine in an area where pedestrians, children and animals are not

likely to come in to contact with the machine.

1.82 Avoid placing any flammable materials near the exhaust outlet during

operation.

1.83 Keep the machine at least 1m from buildings or other equipment as this may

cause the engine to overheat.

1.84 Avoid operating the engine with a dust cover.

1.85 When the oil falls below the lower level the engine will stop automatically.

1.86 Unless you refill with oil the engine will not start again.

1.87 The engine start switch controls the ignition.

1.88 In the ‘OFF’ position the ignition circuit is switched off and the engine will not run.

1.89 In the ‘ON’ position the engine is ready for starting.

1.90 The AC switch (Breaker) will turn ‘OFF’ automatically when the load exceeds the

generator output.

1.91 If the AC switch turns ‘OFF’ then before resetting you must reduce the load and

keep below the rated output of the machine.

1.92 DO NOT connect to and AC outlets – commonly known as ‘back feeding’.

This is extremely dangerous.

MACHINE SPECIFIC SAFETY

8

CAUTION

Pre-operation checks should be carried out each time the generator is used.

WARNING

All fuels are flammable

ALWAYS fuel and defuel in a well ventilated area outside of buildings.

ALWAYS wear the correct Personal Protective Equipment (PPE) when handling

fuels.

2.0 Fuel

2.1 Check the fuel level via the fuel filler cap.

2.2 If the fuel level is low, refill with fresh unleaded petrol.

2.3 Make sure you use the fuel filter screen on the fuel filler neck.

Model Number

Capacity

HY8500

6.0 Litres

HY10000

6.0 Litres

HY220DC

6.0 Litres

2.4 Check engine oil

2.5 Before checking the engine oil, make sure the generator is put on stable, level

ground.

2.6 Remove the oil filler cap and check engine oil level.

2.7 If the oil level is below the lower level line, refill with 15w40 oil to the upper level.

N.B. do not screw the filler cap on when checking oil level.

2.8 Change contaminated oil.

2.9 Oil capacity.

Model Number

Capacity

HY8500

1100ml

HY10000

1100ml

HY220DC

1100ml

2.10 Earthing (Ground)

2.11 This generator is supplied with a ‘floating earth’.

2.12 It is therefore extremely important that you only use the generator to power

equipment in the following permutations;

1 or more Class 2 equipment or,

1 piece of Class 1 equipment or,

1 or more Class 2 equipment and 1 piece of Class 1 equipment.

2.13 Class 1 equipment uses an earth wire.

2. PRE-OPERATION CHECKS

9

2.14 Class 2 equipment (also known as double insulated) does NOT use an earth wire

and will have the following symbol on it:

2.15 If the generator is to be used in a more permanent location then it is advisable to

connect the generator to an earth road or earth point.

DO NOT put an earth rod into the ground until you have checked that it is safe to do

so. We strongly suggest that you contact a qualified electrician to assist you.

10

1. Air filter 2. Fuel filler cap 3. Choke lever 4. Fuel tap

5. Recoil starter 6. 230V 16A socket 7. Engine switch 8. Oil drain plug

9. Oil filler/dipstick 10.115V 16A sockets 11. Spark plug 12. Oil filler/dipstick

13. Voltage selector 14. Exhaust

2. PART LOCATIONS

2

1

6

9

7

3

10

12

13

14

8

5

11

4

11

WARNING

All fuels are flammable

ALWAYS fuel and defuel in a well ventilated area outside of buildings.

ALWAYS wear the correct Personal Protective Equipment (PPE) when handling

fuels.

DO NOT smoke around fuel or fuel vapours and ensure when you are fuelling that

you are clear of any other sources of ignition.

3.0 Fuelling

3.1 This machine uses fresh Unleaded Petrol only. No additives are required.

3.2 Clean the area around the fuel filler cap to ensure no dirt or debris enters the fuel

system during refuelling.

3.2 Remove the fuel filler cap (1).

3.3 Pour the fuel carefully through the filter screen in the filler neck (2).

3.4 DO NOT over fill the fuel tank, fill to the level indicated by the red fill mark on the

filter screen (3).

3.5 Replace the fuel filler cap and ensure it’s on securely.

3.6 Clean up any spills before operation.

3.7 NEVER refuel when the engine is running or warm as this can cause explosion or

fire.

3. FUELLING & OIL

1

2

3

12

WARNING

This machine is shipped WITHOUT OIL and will require filling BEFORE operation.

3.8 The engine requires SAE15W40 oil.

3.9 Place the generator on flat level ground.

3.10 Clean the area around the oil filler.

3.11 Unscrew and remove the oil filler cap/dipstick.

3.12 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.

3.13 Stop filling occasionally to check the oil level.

3.14 Refit the oil filler cap and make sure the cap is tightened.

3.15 You MUST check the engine oil level before starting every session.

13

NOTE

Before starting the engine;

DO NOT connect any electrical appliance to the machine.

Check fuel and oil levels are correct.

4.0 Turn the fuel tap to the ‘ON’ position (1).

4.1 Turn the engine switch to the ‘ON’ position (2).

4.2 Slide the choke lever to the ‘START’ position (3).

NOTE: This procedure is not required if the engine is already warm.

4.3 Pull the recoil starter handle (1) slowly until resistance is felt and then pull the handle

up swiftly.

4.4 After starting, allow the recoil starter handle to return to its original position while still

holding the handle.

4.5 Allow the engine to warm up.

4.6 Turn the choke lever back to the ‘RUN’ (2) position.

4.7 Continue to allow the engine to warm up for a few minutes without load.

4. STARTING PROCEDURE

1

2

3

1

2

14

4.8 Turn ‘OFF’ and unplug all appliances attached to the machine.

4.9 Allow the engine to run at idle for a minute.

4.9 Turn the engine switch to the ‘OFF’ position.

4.10 Turn OFF the fuel tap.

CAUTION

Make sure the electrical apparatus to be powered is turned ‘OFF’ before plugging

into the socket outlet.

CAUTION

DO NOT overload the generator.

DO NOT overload individual sockets.

5.0 Overloading a generator in excess of its rated wattage capacity can result in damage

to the generator and to prevent overloading of the circuit.

5.1 Add up to total wattage of all electrical devices to be connected at one time. This

total should NOT be greater than the generators wattage capacity.

5.2 The rated wattage of lights can be taken from the light bulbs. The rated wattage of

tools, appliances and motors can usually be found on the data label or decal affixed

to the devices.

If the appliance, tool or motor does not give wattage, multiply volts by ampere rating

to determine watts (volts x amps = watts).

5.3 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 your generator.

5.4 DO NOT change the voltage changeover switch whilst the engine is running.

5.5 Make sure the electrical apparatus to be powered is turned ‘OFF’ before plugging

into socket outlet.

5. USING THE MACHINE

STOPPING PROCEDURE

15

WARNING

Shut off the engine before performing any maintenance.

Always carry out maintenance in a clean and well ventilated place and follow all

safety precautions when handling fuels or oil.

Always wear the appropriate Personal Protective Equipment.

NOTE

Use only genuine parts or their equivalent for maintenance or repair.

Substandard replacement parts may damage the generator.

Service more frequently in dusty environments.

6.0 Periodic Maintenance.

MAINTENANCE SCHEDULE

After first 10 hours of use

Change the engine oil – use

SAE15W40

Before every use

Check oil level

Check fuel level

Check for leaks, damage or loose

fittings

Clean the machine

Every 20 hours or Monthly

Change engine oil

Clean the Air Filter

Every 50 hours or 3 Months

Check the Spark Plug

Every 100 hours or 6 Months

Check the Fuel Filter

Check the Exhaust System

Check for and loose fasteners or fixings

Change the Engine Oil – use

SAE15W40

Annually

Replace the Air Filter

Service / Replace the Fuel Filter

Service / Replace the Spark Plug

Check the exhaust system

6. MAINTENANCE

16

6.1 Engine Oil Replacement

CAUTION

After the engine has been run, the oil will be very hot.

Wear the correct PPE to avoid injury.

DO NOT allow any dirt or debris to enter the crankcase via the oil filler/dipstick hole.

NOTE

Please dispose of used motor oil in a matter that is compatible with the

environment.

We suggest taking it in a sealed container to your local recycling centre for

reclamation.

DO NOT throw waste oil on to the ground or down drains.

6.2 Place the generator on a level, firm surface and warm up the engine for several

minutes. Then stop the engine.

6.3 Remove the oil filler/dipstick cap.

6.4 Place an oil pan under the engine.

6.5 Remove the oil drain plug so that the oil can be completely drained.

6.6 Check the oil drain plug, gasket and O-ring. If damaged then replace.

6.7 Reinstall the oil drain plug.

6.8 Add SAE15W40 engine oil to the upper level.

17

6.10 Air Filter Replacement

NOTE

A dirty air filter will restrict air flow to the carburetor. To prevent carburetor

malfunction, service the air cleaner regularly. Service more frequently when

operating the generator in dusty areas.

WARNING

Never use petrol or low flash point solvents for cleaning the air filter element. This

could result in a fire or explosion.

NOTE

Never run the engine without an air filter. Rapid engine wear will result from

contaminants such as dust and dirt being drawn in to the engine.

6.11 Unscrew the wing nut and remove the air filter cover (1).

6.12 Unscrew and remove the foam air filter element from the housing (2).

6.13 If there is light dust on the filter it can be blown clean with an airline.

6.14 Ideally the air filter should be replaced if dirty.

6.15 To reinstall, reverse the process.

6.20 Spark plug replacement

6.21 CAUTION

Allow the engine and spark plug to cool down before removing the spark plug.

6.22 Remove the HT lead (1).

6.23 Using the supplied spanner, undo the spark plug (2) in an anti-clockwise direction.

6.24 If the spark plug is to be cleaned and reused, check for any damage or wear.

The spark plug electrode should be a tan colour.

6.25 Clean with a soft wire brush.

1

2

3

18

6.26 Check and set the gap on the spark plug to 0.7 – 0.8mm.

6.27 Replace the spark plug with a suitable replacement if required.

6.28 Check the spark plug washer is in good condition.

6.29 Thread the spark plug back in to the engine by hand taking care to prevent cross

threading.

6.30 Once the spark plug has been installed as tight as you can by hand and is seated

correctly, tighten with a spark plug wrench to compress the washer.

New Plug: ½ a turn

Re-Used Plug: ⅛ – ½ a turn

6.40 Fuel tank filter

6.41 Remove fuel filler cap.

6.42 Remove the fuel filter and clean.

6.43 Wipe off and dry with a clean, lint free cloth.

6.44 Replace fuel filter in to the fuel tank filler neck.

6.50 Exhaust

WARNING

The exhaust becomes very hot during operation and remains hot for a while after

use. Allow the exhaust to cool before carrying out any maintenance.

6.51 Make sure the exhaust is cold before continuing work.

6.52 Remove the silencer protector and silencer screen.

6.53 Clean the carbon deposits from the exhaust outlet using a soft wire brush.

6.54 Replace the exhaust silencer protector and silencer screen.

0.7 – 0.8mm

1

2

19

7.0 Engine - All corrective actions should be carried out by suitability qualified person/s.

Condition

Possible cause/s

Corrective action/s

Engine will

not start or

low engine

output.

Engine

runs

erratically.

Insufficient

compression

Loose spark plug

Loose cylinder head bolt

Damaged 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

carburetor

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

7.1 Generator - All corrective actions should be carried out by suitability qualified person/s.

Condition

Possible cause/s

Corrective action/s

No AC output

Circuit breaker tripped

Reset breaker

Poor connections or broken

wire/s

Check and repair

Broken output socket

Faulty circuit breaker

No AC output

Generator problem

Contact dealer

Internal generator problem

Contact dealer

7. TROUBLESHOOTING

20

8.0 Draining the fuel system.

WARNING

All fuels are flammable and the proper precautions and procedures must be followed

when handling fuels as they are a source of fire or explosion.

Fuel must always be stored in the proper containers.

WARNING

When working with fuels you must always work in a well ventilated areas and avoid

breathing petrol fumes.

8.1 With the fuel valve OFF, remove the carburetor drain screw.

8.2 Drain the fuel from the carburetor into a suitable container.

8.3 If the fuel in the fuel tank is to be drained, turn the fuel valve ON and drain the fuel

from the fuel tank in to a suitable container.

8.4 Replace the drain screw and turn the fuel valve to the OFF position.

Stoppage Time

Recommended service procedure to prevent hard starting

Less than 1 month

No preparation required

1 to 2 months

Fill with fresh fuel

2 months to 1 year

Fill with fresh fuel

Drain the carburetor float bowl

1 year or longer

Drain the fuel tank

Drain the carburetor float bowl

Pour 5ml of oil down the cylinder bore

Fill with fresh fuel

Use fuel conditioners that are formulated to extend storage life.

8.5 Remove the spark plug and pour a tablespoon of clean engine oil into the cylinder

bore. Crank the engine a few revolutions to distribute the oil then reinstall the spark

plug.

8.6 Slowly pull the recoil starter handle until resistance is felt. At this point the piston is

coming up on its compression stroke and both intake and exhaust valves are closed.

Storing the engine in this position will help to protect it from internal corrosion.

8.7 Change the engine oil.

8.8 Check the air filter and clean as necessary.

8.9 Cover the generator with a sheet to keep out dust.

7. STORAGE

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