Hyundai Hirepro HY220DC User manual

Category
Power generators
Type
User manual

This manual is also suitable for

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
HY8500
HY10000
HY220DC
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 turnedOFF’ 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 turnedOFF’ 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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Hyundai Hirepro HY220DC User manual

Category
Power generators
Type
User manual
This manual is also suitable for

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