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Hyundai DHY6000SE, Service Manual

The Hyundai DHY6000SE is a powerful and reliable generator equipped with a 5.2kW output, perfect for both domestic and commercial use. To ensure optimal performance and maintenance, make sure to download the free Service Manual and user manual from our website for detailed instructions on how to use and care for this exceptional product. {Website} offers hassle-free access to these invaluable resources.

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Changzhou ITC Power Equipment Manufacturing Co.,Ltd.

Changzhou ITC Power Equipment Manufacturing Co.,Ltd.

Changzhou ITC Power Equipment Manufacturing Co.,Ltd.

Changzhou ITC Power Equipment Manufacturing Co.,Ltd.

Changzhou ITC Power Equipment Manufacturing Co.,Ltd.

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

Summary of Contents for DHY6000SE

Page 1: ...DIESEL GENERATOR SERVICE MANUAL Licensed by Hyundai Corporation Seoul South Korea OPEN TYPE DHY6000LE DHY6000LE 3 SOUNDPROOF TYPE DHY6000SE DHY6000SE 3 ...

Page 2: ... 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 f...

Page 3: ...kshaft 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 s...

Page 4: ...nent 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 ...

Page 5: ...Y6000SE 3 Changzhou ITC Power Equipment Manufacturing Co Ltd Changzhou ITC Power Equipment Manufacturing Co Ltd POWER PRODUCTS FUEL TANK CAP HOOK CONTROL PANEL AC OUTPUT SOCKET PUSH WHEELS FRONT DOOR FUEL LEVEL INDICATOR MUFFLER 2 ...

Page 6: ...TERMINALS GROUND TERMINAL GROUND TERMINAL 12V DC SOCKET SOCKET PRE HEATER BUTTON PRE HEATER BUTTON ATS SIGNAL SOCKET ATS SIGNAL SOCKET 12V DC FUSE 12V DC FUSE IP66 WATERPROOF COVER Changzhou ITC Power Equipment Manufacturing Co Ltd Changzhou ITC Power Equipment Manufacturing Co Ltd POWER PRODUCTS OPEN TYPE DHY6000LE SUNDPROOF TYPE DHY6000SE 3 ...

Page 7: ...tralian 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 Mod...

Page 8: ...can 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 4...

Page 9: ...l code E electric start D400 D400 Air cooled diesel engine Performance Performance Curves Curves Dimensions Dimensions PTO PTO Dimensions Dimensions Engine Engine Flagers Flagers PTO PTO Keyway shaft Keyway shaft Thread shaft Thread shaft Taper shaft Taper shaft Crankshaft Crankshaft PTO PTO Camshaft Camshaft PTO 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...

Page 10: ...earance 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 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 p...

Page 11: ...mm 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 W...

Page 12: ...ondition Perform the service and inspection at the intervals shown in the Maintenance schedule below Changzhou ITC Power Equipment Manufacturing Co Ltd Changzhou ITC Power Equipment Manufacturing Co Ltd Changzhou ITC Power Equipment Manufacturing Co Ltd Changzhou ITC Power Equipment Manufacturing Co Ltd Changzhou ITC Power Equipment Manufacturing Co Ltd WARNING 1 Service more frequently when used ...

Page 13: ...lace 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...

Page 14: ... 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 th...

Page 15: ...ng Co Ltd Changzhou ITC Power Equipment Manufacturing Co Ltd 12 POWER PRODUCTS 2 2 5 Adjust the valve clearance 1 The clearance must be adjusted when the engine is cold t i m i L e c n a n e t n i a M d r a d n a t S m m 5 1 e c n a r a e l c t s u a h x E e k a t n I 2 Valve timing C D T e r o f e b 4 1 n e p O Intake Close 50 after BDC C D B e r o f e b 4 5 n e p O Exhaust Close 10 after TDC ...

Page 16: ...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 ...

Page 17: ... Equipment Manufacturing Co Ltd Changzhou ITC Power Equipment Manufacturing Co Ltd 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 ...

Page 18: ... Equipment Manufacturing Co Ltd Changzhou ITC Power Equipment Manufacturing Co Ltd 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 ...

Page 19: ...ipment Manufacturing Co Ltd 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 co...

Page 20: ...h s m a C 6 1 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 3 Turn the crankshaft to the top of stroke and take out the pis...

Page 21: ...turing Co Ltd 18 POWER PRODUCTS 3 1 19 Flywheel 1 Loosen the flywheel nut 2 Remove the flywheel Use flywheel extractor Securely thread in the extractor bolts 3 1 20 Crankshaft 1 Remove the flywheel key 2 Remove the main bearing thrust plate 3 Pull out the crankshaft taking care not to damage the oil seal 3 1 21 Governor 1 Remove the governor or speed control device only if necessary 2 Note the pos...

Page 22: ...t o t s t l o b 3 2 1 Assemble governor or speed control device Reassemble the governor or speed control device if it has been removed 3 2 2 Crankshaft 1 Insert the crankshaft 2 Install the main bearing thrust plate 3 Attach the flywheel key to crankshaft Be sure crankshaft is in proper position Apply grease to the oil seal lips Apply lube oil to the crankshaft journal and crank pin 3 2 3 Flywheel...

Page 23: ...ft 1 Insert the tappets 2 Insert the cam shaft 3 Insert the balance shaft Do not confuse the intake and exhaust tappets Check whether the matching marks of gear are aligned correctly 3 2 6 Crankcase cover 1 Place an aluminum washer between the surface of crankcase and the cover 2 Reassemble the crankcase cover Tighten bolts in a diagonal sequence To protect the oil seal attach a jig for inserting ...

Page 24: ... 2 Insert the governor lever into the fork groove of the governor 3 Install only one locating nut to the fuel injection pump Be sure the quantity and thickness of spacer shims are correct 3 2 8 Assemble the fuel injection pump final assembling Tighten the lock bolt of the fuel injection pump Fuel Injection Pump Lock Bolt Tightening Torque 10 12 N m Tightening torque of fuel injection pump lock bol...

Page 25: ... 22 POWER PRODUCTS Tightening torque of cylinder head bolts s e u l a V e u q r o T d a e H r e d n i l y C e u q r o t l a i t i n I 30 N m m N 8 5 4 5 e u q r o t l a n i F 3 2 10 Push rod Insert the push rod and check whether it is in proper position 3 2 11 Rocker arm assembly 1 Reassemble the rocker arm assembly 2 Adjust the valve clearance to 0 0006in 015mm cold Tightening torque of air valve...

Page 26: ...Fuel injector 1 Install the fuel injector assembly 2 Tighten the lock bolts 3 Install the high pressure fuel line Be sure the installation direction of fuel injector is correct Replace the nozzle washer when reassembling Injector Tightening Torque 10 12 N m 3 2 14 Air inlet pipe Install the air inlet pipe and ensure the washer is in proper position 3 2 15 Cooling fan case 1 Install the starter ree...

Page 27: ...the air cleaner bottom case 2 Install the element 3 Install the air cleaner cover Check whether the inlet pipe and gaskets are in the proper position 3 2 17 Starting motor Install the electric starting motor 3 2 18 Exhaust muffler Install the exhaust muffler 3 2 19 Fuel tank 1 Join fuel line and the fuel injection pump 2 Fix the fuel tank with the upper support 3 Connect the fuel return pipe to th...

Page 28: ...ter reel attaches the end of the starter rope stop the reel with your finger and pull the rope out with an awl as show below in figure a Put your finger on the gap to push the reel for returning the rope until the reel stop moving 3 Disassemble all parts as shown in figures b d 4 Remove the starter reel from the case as shown in figure e then remove the spring 3 3 2 Reassembly 1 Check whether the ...

Page 29: ...ter rope as shown in figure h Securely hold the reel so that the rope cannot reverse and wind the starter rope 4 revolutions in the arrow direction shown in figure h Cross the rope from the inside to outside Run the reel slowly in an opposite direction of the arrow 4 Reassemble the parts removed in figure g in the opposite order of disassembly Pull the return spring while assembling the friction p...

Page 30: ...el does not move check whether the spring is in proper position 2 Pull out the starter rope completely If the rope blocks the starter reel or it does not return it indicates that the spring has inadequate tension Wind the rope one or two more revolutions per the procedure shown in figure a If the returning power of the starter rope is too low or the handle dropped in half way it is necessary to lu...

Page 31: ...r damage 4 1 2 Inlet and exhaust valve seats Freeze the valve seat with liquid nitrogen for improving durability then insert it into the cylinder head Wipe off the carbon deposit from the valve seat t i m i L e c n a n e t n i a M d r a d n a t S 5 4 e l g n a e c a f r u s t a e S Seat surface width 1 5 3 mm 4 1 3 Inlet exhaust valve and valve guides 1 Check the wearing and distortion of the valv...

Page 32: ...e 4 Remove the cylinder head and take out the flattened fuse then measure the thickness of the fuse On the other side you can tie three fuses with three threads respectively then cross them out from the nozzle hole as per the below figure thus it s not necessary to remove the cylinder head Finally measure the thickness of the flattened fuses as from 3 5 The top clearance of the piston is the avera...

Page 33: ... a n e t n i a M d r a d n a t S m m 5 1 e c n a r a e l c t s u a h x E e k a t n I 2 Valve timing C D T e r o f e b 4 1 n e p O Intake Close 50 after BDC C D B e r o f e b 4 5 n e p O Exhaust Close 10 after TDC 4 2 Piston and piston pin 4 2 1 Piston 1 Check the top of piston and the surface of combustion chamber To wipe off the carbon from the top of piston and the surface of combustion chamber ...

Page 34: ...uter diameter if it worn out beyond the maintenance limit or already distorted into ladder shape it should be replaced t i m i L e c n a n e t n i a M d r a d n a t S Outer diameter of the piston pin 22 991 23 000 mm 22 91 mm 4 2 3 Piston Bore 1 If the bore is warped elongated or otherwise damaged it must be replaced 2 Measure the inner diameter of the bore and replace it if the inner diameter exc...

Page 35: ...Check distortion of the large and small end holes for being parallel and distortion Pass the measuring jigs through the large end and small end holes of the connecting rod to measure if the jigs are parallel or distored Replace the connecting rod if it distorted beyond the permitted limit Parallelism or distortion Standard Maintenance Limit m m 5 0 5 3 2 Check the crankshaft bushing 1 Check whethe...

Page 36: ...r cracks by magnafluxing Replace if any cracks are discovered 2 Measure the crank pin and the main journal Check the condition of the crank pin and the main journal Replace the crankshaft assembly if the wear has exceeded the permitted limit 3 The balling bearing on the flywheel side has been pressed onto the crankshaft and is an integral part of the crankshaft Replace the crankshaft assembly if t...

Page 37: ...ace of the pressed bearing and the thrust surface of the cylinder body at 1 4 1 5mm 4 5 2 Tappet 1 Check the condition of the tappet contacts The tappet offsets from the cam center and rotates during operation to prevent uneven wearing If the tappet is worn seriously or the contact with the cam is uneven the tappet must be replaced 2 Check the outer surface of tappet and replace it if the outer su...

Page 38: ...ER PRODUCTS 35 4 7 Crankcase cover Be careful of the aluminum gasket while disassembling replace it if it damaged or distorted Furthermore be sure to tighten the crankcase cover bolts with the specified tightening torque below Crankcase cover bolt tightening torque 20 23 N m 4 7 1 Cleaning and inspection Rinse the cylinder block before reassembly Thoroughly clean every oil passage to ensure there ...

Page 39: ...installation tool Push the crankshaft oil seal into the crankcase cover until the both faces are even Push the rear oil seal of the crankshaft into the cylinder body ensuring both faces are even 4 8 Cylinder sleeve and cylinder block 4 8 1 Cylinder sleeve Measure the inner diameter of cylinder sleeve bore if it exceeds the permitted limit and replaced by an oversized piston Oversized pistons are a...

Page 40: ...the crankcase cover Replace the lube oil pump if the clearance exceeds the permitted limit 2 Measure the clearance between the outer rotator and the inner rotator of the lube oil pump with feeler gauge and replace the full set of lube oil pump if the clearance exceeds the permitted limit 3 Assemble the lube oil pump Insert the lube oil pump from the outside of the crankcase cover Insert the pin in...

Page 41: ...y Put the fuel injection valve on a fuel injection valve test stand and run the handle of the tester at the speed of approx 1 2 times second to check the spray pattern 3 Normal shape of injection spray 1 The injection spray angle injected from all four orifices should be same 2 Sprayed oil should resemble a fine mist 3 Injection spray from all four orifices should be steady and smooth 4 Take the f...

Page 42: ...ut the fuel spraying pressure can be adjusted by adding or reducing spacer shims The fuel spraying pressure will change 28 4 psi or 20kg cm2 when adding or removing one 0 1mm shim Shims are available in 0 1mm 0 3mm 0 4mm 0 5mm and 0 6mm 4 10 3 Fuel filter Check the element whether it cracked varnished or clogged during the periodic check and replace it if any fault found To disassemble the fuel fi...

Page 43: ...low turn the flywheel one complete revolution Turn the flywheel slowly until the fuel flows from the testing pipe Immediately check the mark angle of the flywheel with the scale mark of cylinder Repeat the foregoing process three times to ensure the validity of the final value 2 How to adjust the fuel injection timing Disassemble the fuel injection pump and the construction flange Add spacer shims...

Page 44: ...e fuel line from the injection pump to the injector Pull the recoil starter or engage the electric starter until the fuel flow is steady Retorque the fuel line Repeat this step until the unit starts and runs Be sure to contain any diesel fuel that spills as a result of this process 4 12 3 Adjust the valve clearance Check the valve clearance every time after disassembly or after 500 hours operation...

Page 45: ...ck the injection pump stud If worn replace the pump d Clogged injector nozzle test and clean e Check torque of injector nut f Verify proper injection pressure adjust or replace injector 5 3 Low engine compression a Intake or exhaust valve leaking adjust valve clearance b Valve seats worn replace c Fuel injector not properly torqued retorque d Fuel injection nozzle gasket leaking d Cylinder head ga...

Page 46: ...e Wrong fuel injection timing 1 Improper spacer shim thickness 2 The fuel injection pressure is false 3 The plunger worn out 1 Adjust the thickness of the spacer shim 2 Adjust the fuel injection pressure 3 Replace the plunger 1 Adjust the fuel injection timing 2 Dispose of diesel fuel properly Bad atomization of the injection nozzle 1 The injection nozzle clogged 2 The fuel injection nozzle has a ...

Page 47: ...ective 1 Adjust the governor lever 2 Retorque bolt 3 Replace defective part Follow the proper method of adjusting the governor lever 5 7 Unsteady engine speed Cause and remedy y d e m e R e s u a c n i a M Governor fault See governor adjustment above Low quality diesel fuel or dirty fuel See section 6 5 on hard starting Bad atomization of the injection nozzle See section 6 5 on hard starting Bad f...

Page 48: ...uring Co Ltd Changzhou ITC Power Equipment Manufacturing Co Ltd Changzhou ITC Power Equipment Manufacturing Co Ltd Changzhou ITC Power Equipment Manufacturing Co Ltd Changzhou ITC Power Equipment Manufacturing Co Ltd POWER PRODUCTS 45 6 6 1 ...

Page 49: ...Changzhou ITC Power Equipment Manufacturing Co Ltd Changzhou ITC Power Equipment Manufacturing Co Ltd Changzhou ITC Power Equipment Manufacturing Co Ltd Changzhou ITC Power Equipment Manufacturing Co Ltd POWER PRODUCTS 46 GREEN GREEN BLACK BLACK YELLOW ...

Page 50: ...acturing Co Ltd Changzhou ITC Power Equipment Manufacturing Co Ltd Changzhou ITC Power Equipment Manufacturing Co Ltd Changzhou ITC Power Equipment Manufacturing Co Ltd Changzhou ITC Power Equipment Manufacturing Co Ltd POWER PRODUCTS 47 ...

Page 51: ...ng Co Ltd Changzhou ITC Power Equipment Manufacturing Co Ltd Changzhou ITC Power Equipment Manufacturing Co Ltd Changzhou ITC Power Equipment Manufacturing Co Ltd Changzhou ITC Power Equipment Manufacturing Co Ltd POWER PRODUCTS 48 D400 BLACK ...

Page 52: ...nt Manufacturing Co Ltd Changzhou ITC Power Equipment Manufacturing Co Ltd Changzhou ITC Power Equipment Manufacturing Co Ltd Changzhou ITC Power Equipment Manufacturing Co Ltd Changzhou ITC Power Equipment Manufacturing Co Ltd POWER PRODUCTS 49 ...

Page 53: ...acturing Co Ltd Changzhou ITC Power Equipment Manufacturing Co Ltd Changzhou ITC Power Equipment Manufacturing Co Ltd Changzhou ITC Power Equipment Manufacturing Co Ltd Changzhou ITC Power Equipment Manufacturing Co Ltd POWER PRODUCTS 50 ...

Page 54: ...ngzhou ITC Power Equipment Manufacturing Co Ltd Changzhou ITC Power Equipment Manufacturing Co Ltd Changzhou ITC Power Equipment Manufacturing Co Ltd Changzhou ITC Power Equipment Manufacturing Co Ltd POWER PRODUCTS 51 7 Circuit Diagram Open type DHY6000LE ...

Page 55: ...o Ltd Changzhou ITC Power Equipment Manufacturing Co Ltd Changzhou ITC Power Equipment Manufacturing Co Ltd Changzhou ITC Power Equipment Manufacturing Co Ltd Changzhou ITC Power Equipment Manufacturing Co Ltd POWER PRODUCTS 52 Open type DHY6000SE ...

Page 56: ...acturing Co Ltd Changzhou ITC Power Equipment Manufacturing Co Ltd Changzhou ITC Power Equipment Manufacturing Co Ltd Changzhou ITC Power Equipment Manufacturing Co Ltd Changzhou ITC Power Equipment Manufacturing Co Ltd POWER PRODUCTS 53 ...

Page 57: ...cturing Co Ltd Changzhou ITC Power Equipment Manufacturing Co Ltd Changzhou ITC Power Equipment Manufacturing Co Ltd Changzhou ITC Power Equipment Manufacturing Co Ltd Changzhou ITC Power Equipment Manufacturing Co Ltd POWER PRODUCTS 54 8 ...

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