Hyundai DHY6000LE User manual

DIESEL GENERATOR

SERVICE MANUAL

Licensed by Hyundai Corporation, Seoul, South Korea

OPEN TYPE: DHY6000LE / DHY6000LE-3

SOUNDPROOF TYPE: DHY6000SE / DHY6000SE-3

This manual contains information how to maintain and how to do troubleshooting.

Keep this owner’s manual handy, so you can refer to it at any time.

This service manual describes correct method of the maintaining this equipment. As a result of

this disregard of our rules caused by person casualty and equipment damaged, our company

does not assume any responsibility.

NOTICE:

Copyright reserved, and no part of this publication may be reproduced without our

Company’s written permission.

SAFETY MESSAGES

Your safety and the safety of others are very important. We have provided important safety

mes3ges in this manual and on the generator. Please read these messages carefully.

A safety message reminds 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 mean:

You WILL be KILLED or SERIOUSLY 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.

Your generator or other property could be damaged

if you don’t follow instructions.

NOTICE

DANGER

WARNING

CAUTION

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POWER PRODUCTS

1 PREFACE 1

1-1 Generator Component Identification 1

1-2 Control Panel 3

1-3 Specifications of generator 4

1-4 Specifications of engine 6

1-5 Maintenance Standard 7

2 Periodic Maintenance 9

2.1 Service Intervals 9

2.2 Routine Maintenance Procedures 10

3. Engine Disassembly and Reassembly 13

3.1 Disassembly 13

3.2 Reassembly 19

3.3 Recoil Starter Assembly 25

4. Inspection and Service 28

4.1 Cylinder Head 28

4.2 Piston and Piston Pin 30

4.3 Connecting rod 32

4.4 Crankshaft, main bearing and flywheel 33

4.5 Camshaft 34

4.6 Timing Gear 34

4.7 Crankshaft Cover 35

4.8 Cylinder Sleeve and Block 36

4.9 Lubricating System 36

4.10 Fuel System 38

4.11 Governor 39

4.12 Adjustments 40

5. Troubleshooting 42

5.1 No fuel delivery to injection pump 42

5.2 No fuel flow from drain valve 42

5.3 Low compression 42

5.4 Hard starting (fuel delivery and compression normal) 42

5.5 No start or hard start (engine cranks) 42

5.6 Engine over speed 43

5.7 Unsteady engine speed 44

5.8 Unexpected shutdown 44

6 Generator 45

6.1 Removal/Installation 45

7 Circuit diagram 51

8 Appendix 53

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POWER PRODUCTS

CONTENTS

Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.

1. PREFACE

1-1 Generator Component Identification

Open Type: DHY6000LE, DHY6000LE-3

1

FUEL TANK

FUEL TANK CAP

CONTROL PANEL

UP COVER

FRAME

DIESEL ENGINE

RECOIL STARTER

INJECTION PUMP

SPEED GOVERNOR

COCK OF OIL DRANING

OIL PUMP

BATTERY

BOTTOM FRAME

RUBBER ABSORBER

ALTERNATOR

PUSH WHEEL KIT

MUFFLER

START MOTOR

BATTERY CHARGER

OIL DIPSTICK

AIR CLEANER

POWER PRODUCTS

Soundproof Type: DHY6000SE, DHY6000SE-3

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POWER PRODUCTS

FUEL TANK CAP

HOOK

CONTROL PANEL

AC OUTPUT SOCKET

PUSH WHEELS

FRONT DOOR

FUEL LEVEL INDICATOR

MUFFLER

2

LED4 DISPLAY

ELECTRIC START KEY

1-2 CONTROL PANEL

E-STOP BUTTON

LEAKAGE BREAKER

PCB

12V DC TERMINALS

GROUND TERMINAL

12V DC SOCKET

SOCKET

PRE-HEATER BUTTON

ATS SIGNAL SOCKET

12V DC FUSE

IP66 WATERPROOF

COVER

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POWER PRODUCTS

OPEN TYPE: DHY6000LE

SUNDPROOF TYPE: DHY6000SE

3

1-3 Specifications of generator

Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.

Hz

kVA

kW

kVA

V

A

L

Hours

dBA

Hp

cc

L

kVA

cosφ

kg

mm

unit / container

DHY6000LE

50 / 60

4.5 / 5.0

5.0 / 5.5

230 / 240

19.6 / 20.8

1- phase

Electric & Manual

14

5.2

79

12V/36Ah

D400E

10.0

Electric & Manual

418

1.65

5kVA 190L-138/D50(D60)

5

1

Blush type / AVR

140

147

DHY6000LE-3

50 / 60

5.6 / 6.3

4.5 / 5.0

6.2 / 6.9

230 / 240

8.1 / 8.6

3- phase

Electric & Manual

14

5.2

79

12V/36Ah

D400E

10.0

Electric & Manual

418

1.65

6.3kVA 190L-138/D50(D60)

6.3

0.8

Blush type / AVR

142

149

Electrical standard and options

DHY6000LE DHY6000LE-3

1-phase (2×15A Australian sockets)

3-phase (1×15A Australian socket )

American;UK;European sockets;etc

Display LED4

Display LED3

Prosice overload protection

Common overload protection

DC output:12V / 8.3A

Earth connection

Pre-heater

ATS sensor

Remote control

ATS control box(50A)

Mechanical standard and options

Frame tube diameter 32mm

Basic color Pantone black C

Alternator Steel plate Q195

Alternator Silicon steel plate DW800

Push wheel kit

●

×

○

●

○

●

○

●

○

●

○

×

●

○

●

○

●

○

●

○

●

○

Generator Model

Frequency

Rated power

Max. power

Voltage

Rated current

Phase

Start mode

Fuel tank capacity

Fuel consumption 50% load

Sound pressure level(7m 75% load)

Battery

Engine Model

Rated power

Start mode

Displacement

Oil capacity

Alternator Model

Rated power

Power factor

Voltage regulation

Dimension and Weight

Net weight

Gross weight

Product dimension (L×W×H)

Box dimension (L×W×H)

Capacity

720×480×600

740×500×640

99/20GP; 207/40GP; 220/40HQ

Option :

○

Standard feature :

●

No available :

×

4

POWER PRODUCTS

open type

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POWER PRODUCTS

Hz

kVA

kW

kVA

V

A

L

Hours

dBA

Hp

cc

L

kVA

cosφ

kg

mm

unit / container

DHY6000SE

50 / 60

4.5 / 5.0

5.0 / 5.5

230 / 240

19.6 / 20.8

1-phase

Electric

15

6

70

12V/36Ah

D400E

10.0

Electric

418

1.65

5kVA 190L-138/D50(D60)

5

1

Blush type / AVR

170

180

DHY6000SE-3

50 / 60

5.6 / 6.3

4.5 / 5.0

6.2 / 6.9

400 / 420

8.1 / 8.6

3-phase

Electric

15

6

70

12V/36Ah

D400E

10.0

Electric

418

1.65

6.3kVA 190L-138/D50(D60)

6.3

0.8

Blush type / AVR

172

182

Electrical standard and options DHY6000SE DHY6000SE-3

1-phase (2×16A European sockets)

3-phase (1×16A European socket )

American;UK;Australian sockets;etc

Display LED4

Display LED3

Prosice overload protection

Common overload protection

E-stop button

DC output:12V / 8.3A

Earth connection

Pre-heater

ATS sensor

Remote control

ATS control box(50A)

●

×

○

●

○

●

○

●

×

●

○

●

○

●

○

●

○

Mechanical standard and options

Basic color Pantone black C

Alternator Steel plate Q195

Alternator Silicon steel plate DW800

Decompression handle

●

○

●

○

●

○

●

○

920×520×740

960×560×790

48/20GP; 96/40GP; 144/40HQ

Generator Model

Frequency

Rated power

Max. power

Voltage

Rated current

Phase

Start mode

Fuel tank capacity

Fuel consumption 50% load

Sound pressure level(7m 75% load)

Battery

Engine Model

Rated power

Start mode

Displacement

Oil capacity

Alternator Model

Rated power

Power factor

Voltage regulation

Dimension and Weight

Net weight

Gross weight

Product dimension (L×W×H)

Box dimension (L×W×H)

Capacity

Option :

○

Standard feature :

●

No available :

×

soundproof type

5

1-4 Specificat ions of engine

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6

POWER PRODUCTS

D400/E

Single cylinder, vertical, 4-stroke, air-cooled

86x72 (3.39x2.83)

0.418 (418)

19:1

3000 3600

5.9 (8.0) 6.6 (9.0)

6.6 (9.0) 7.3 (10.0)

5.5 (1.45)

≤2.15 (0.57)

1.65 (0.435)

Recoil starter / Elec. starter

crankshaft / camshaft

0#(summer), -10#(winter) diesel

CD grade or SAE10W-30 15W-40

Recoil start=48 (105.6);Elec. Start=53 (117)

417x470x494 (16.42x18.50x19.45)

Diesel Engine Model

Type

BoreXstroke [mm(in)]

Displacement [L(cc)]

Compression ratio

Rated speed (rpm)

Rated power [kW(Hp)]

Max. power [kW(Hp)]

Fuel tank capacity [L(US.gal)]

Fuel consumption [L(US.gal)/hr.

Lube oil capacity [L(US.gal)]

Starting Fashion

Output Shaft

Fuel trademark

Oil trademark

Net Weight [kG(lbs)]

Overall dimension L×W×H [mm(in)]

D: diesel engine 400:model code E: electric start

D400

Air cooled diesel engine

Performance

Curves

Dimensions

PTO

Dimensions

Engine

Flagers

PTO

Keyway shaft

Thread shaft

Taper shaft

Crankshaft

PTO

Camshaft

PTO

417

2.8

2.6

2.4

2.2

2

28

26

24

22

20

Kmg Nm

PS kW

Output

7

6

5

4

3

2

10

9

8

7

6

5

4

3

2

Torque

Sd

6

4

2

0

Smoke Density

Exhaust

Temperature

Specification Fuel

Consumption

°C

600

500

400

300

200

220

210

200

190

180

170

300

280

260

240

220

g/kWh g/PSh

Engine Speed min

-1

1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000 3200 3400 3600 3800 4000

2.8

2.6

2.4

2.2

2

28

26

24

22

20

Kmg Nm

PS kW

Output

7

6

5

4

3

2

10

9

8

7

6

5

4

3

2

Torque

Sd

6

4

2

0

Smoke Density

Exhaust

Temperature

Specification Fuel

Consumption

°C

600

500

400

300

200

220

210

200

190

180

170

300

280

260

240

220

g/kWh g/PSh

Engine Speed min

-1

1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000 3200 3400 3600 3800 4000

7.3kW(10.0hp)

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1-5 Maintenance Standard

Parts Item Standard Service limit

Engine

Maximum Speed (No Load)

Cylinder Compression

3150~3180rpm

≥1.17Mpa(1400rpm)

--

Cylinder Sleeve I.D

Cylinder Head

Cover

Warpage -- 0.10mm

Piston

Skirt O.D.

Piston-to-Cylinder Clearance

Piston Pin Bore I.D.

Piston Pin O.D

Piston Pin-to-Piston Pin Bore Clearance

0.015-0.05mm

18.0mm

0.002-0.014mm

0.12mm

17.954mm

0.06mm

Piston Rings

Ring Side Clearance：

Second

Ring Enc Gap:

Second

Ring Width

Second

0.015-0.045mm

--

0.2-0.4mm

0.15-0.35mm

1.5mm

2.5mm

0.15mm

--

1.0mm

1.37mm

2.37mm

Connecting

Rod

Small End I.D

Big End I.D

Big Oil Clearance

Big End Side Clearance

18.002mm

30.02mm

0.040-0.063mm

0.1-0.7mm

18.07mm

30.066mm

0.12mm

1.1mm

Crankshaft Crankshaft pin O.D 29.98mm 29.92mm

Valve

Valve Clearance IN

EX

Stem O.D IN

EX

Guide I.D

Stem Clearance IN

EX

Seat Width

Spring Free Length

0.15±0.02mm

0.20±0.02mm

5.48mm

5.44mm

5.50mm

0.02-0.044mm

0.06-0.087mm

0.8mm

34mm

--

5.318mm

5.275mm

5.572mm

0.1mm

0.12mm

2.0mm

32.5mm

7

Diesel Engine

Diesel

86.0mm

85.94mm

Ø23mm Ø23.05mm

85.80mm

86.185mm

+0.035

0

-.0002

-0.008

POWER PRODUCTS

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Camshaft

Cam Height IN

Cam Height EX

Journal O.D

27.7mm

27.75mm

13.984mm

27.45mm

27.50mm

13.916mm

Crankcase

Cover

Camshaft Bracket I.D 14.0mm 14.048mm

Carburetor

Main Jet

Float Height

Pilot Screw Opening

#68

13.7±1.5mm

2-1/8 turns

--

Spark Plug Gap 0.7-0.8mm --

Spark Plug

Cap

Resistance 5kΩ --

Ignition Coil

Resistance Primary Coil

Secondary Coil

Air gap

0.8-1.0Ω

5.9-7.1kΩ

0.4-0.6mm

--

y Generator

Parts Item Standard Service limit

Stator Winding Resistance

Stator Winding 1.8±10%Ω at 20℃ --

Stator Auxiliary Winding 3.5±10%Ω at 20℃ --

Rotor Excitation

Winding

Resistance Excitation Winding 51.3±10%Ω at 20℃ --

Carbon Brush Carbon Brush Length 10mm 6mm

8

POWER PRODUCTS

2. Periodic Maintenance

2.1 Service Intervals

Good maintenance is essential for safe, economical, and trouble-free operation. It will also help reduce air

pollution.

Exhaust gas contains poisonous carbon monoxide. Shut off the engine before

perform any maintenance. If the engine must be run, make sure the area is well

ventilated.

Periodic maintenance and adjustment is necessary to keep the generator in good operating condition.

Perform the service and inspection at the intervals shown in the Maintenance schedule below:

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WARNING

(1) Service more frequently when used in dusty areas.

(2) These items should be serviced by an authorized generator dealer.

(3) When more often use, only servicing according to above correct intervals can insure the generator set

long-term use.

9

POWER PRODUCTS

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10

POWER PRODUCTS

DIPSTICK

DRAIN BOLT

2-2 Routine Maintenance Procedures

2.2.1 Oil Change

Drain the used oil while the engine is warm. Warm oil drains quickly and completely.

1. Place a suitable container below the engine to catch the used oil, and then remove

the filler cap/dipstick and the drain plug.

2. Allow the used oil to drain completely, and then reinstall the drain plug, and tighten

it securely.

3. With the engine in a level position, fill to the outer edge of the oil filler hole with the

recommended oil.

2.2.2 Oil Filter Service

Remove the bolt that secures the filter and carefully pull the assembly toward

you.

The filter may be immersed in solvent then blown dry with compressed air.

Replace the filter at the scheduled service interval or anytime the screen is

damaged or all deposits cannot be removed.

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11

POWER PRODUCTS

2.2.3 Air Filter Service

Remove the air cleaner cover and inspect the filter. Clean or replace dirty filter elements.

Always replace damaged filter elements.

2.2.4 Fuel Filter Service

1. Drain out the fuel from the fuel tank. Turn the screw in the drain plug counter

clockwise until fuel flows. Use a suitable container to catch the fuel.

2. Remove the three screws securing the fuel cock assembly and remove the filter

from the housing.

FUEL TANK

DRAIN PLUG

FUEL COCK

FUEL FILTER

ASSEMBLY

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12

POWER PRODUCTS

2.2.5 Adjust the valve clearance

(1) The clearance must be adjusted when the engine is cold.

timiL ecnanetniaM dradnatS

-- mm 51. ecnaraelc tsuahxE/ekatnI

(2) Valve timing

CDT erofeb °41 nepO

Intake

Close

50°after BDC

CDB erofeb °45 nepO

Exhaust

Close

10°after TDC

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13

POWER PRODUCTS

3. Engine disassembly and reassembly

3.1 Disassembly

3.1.1 Fuel tank

1. Release the joint between the fuel line and fuel tank.

2. Release the hose clamp of the fuel line on the pump side.

3. Remove the tank.

3.1.2 Exhaust Muffler

1. Remove the flange bolt

2. Remove the set bolt

3. Discard the muffler gasket. Do not reuse.

3.1.3 Air cleaner

(1). Disassemble the air cleaner cover.

(2). Pull out the element.

(3). Disassemble the air cleaner bottom case.

3.1.4 Recoil starter unit

(do not disassemble)

3.1.5 Disassemble the fan cover

Unbolt and remove the fan cover.

4.1.6 Starter pulley

Unbolt and remove

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14

POWER PRODUCTS

3.1.7 Air inlet pipe

3.1.8 Remove electric starter motor

3.1.9 Remove cylinder head cover

3.1.10 Valve rocker arm seat

3.1.11 Push rods

3.1.12 Fuel injector

(1) Remove the high-pressure fuel line.

(2) Remove fuel injector.

(3) Be careful not to damage the nozzle washer and spacer.

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15

POWER PRODUCTS

3.1.7 Air inlet pipe

3.1.8 Remove electric starter motor

3.1.9 Remove cylinder head cover

3.1.10 Valve rocker arm seat

3.1.11 Push rods

3.1.12 Fuel injector

(1) Remove the high-pressure fuel line.

(2) Remove fuel injector.

(3) Be careful not to damage the nozzle washer and spacer.

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16

POWER PRODUCTS

3.1.13 Remove the cylinder head

3.1.14 Remove the injection pump

(1) Remove the pump together with the base.

(2) Ensure the hooking part of control lever is at the meshing position before

disassembling.

(3) Pull out the flat tappet remaining inside the housing

3.1.15 Crankcase cover

(1) Remove the engine oil injection pump cover.

(2) Remove the engine oil filter cover.

(3). Remove crankcase cover.

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17

POWER PRODUCTS

tfahsmaC 61.1.3

(1) Remove the camshaft taking care not to damage the oil seal.

(2) Note the position of the timing mark

(3) Remove and store the intake and exhaust tappets separately.

3.1.17 Remove balance shaft

3.1.18 Piston and connecting rod assembly

(1) Dismount the forcing nut of connecting rod.

(2) Remove the big end cap of connecting rod.