PRINTSPEC: EN505-2010v1 © 2010 MIDLAND INTERNATIONAL INC.
PREFACE Thank you for purchasing a Hyundai Professional generator. Please register your product in order for us to ensure your continuous satisfaction with our product. This manual covers the safety, operation and maintenance procedures for the HPG4000, HPG6500 and HPG7500 models. All information in this publication is based on the latest product information available at the time of approval for printing. No part of this publication may be reproduced without written permission.
CONTENTS 1.0 SAFETY PRECAUTIONS....................................................................................................................................... 1.1 Safety Labels....................................................................................................................................... 1.2 Operations Safety ............................................................................................................................. 1.3 AC Safety Guidelines ...................
1.0 SAFETY PRECAUTIONS 1.1 SAFETY LABELS 1.2 OPERATIONS SAFETY • • • • • • • • • • • • • • • • • Always perform a pre-operation check before starting the engine. Properly clean and maintain the equipment. Operate the generator according to instructions for safe and dependable service. Before operating the generator, read the user manual carefully. Otherwise, it may result in personal injuries or equipment damage.
1.4 MAINTENANCE SAFETY • • • • • • • • • • After any maintenance is performed, wash your body immediately using soap and clean water because repeated exposure to lubricant may cause skin irritation. Do not clean the filter element with flammable liquids like gasoline because explosion may occur. Turn off the generator set before performing any maintenance. Otherwise it can cause severe personal injury or death. Allow the generator set to cool down before performing any maintenance.
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PANEL LABELS Engine Switch Low 120V AC Voltage 120/240V Oil Light Receptacle Selector Twistlock Switch Receptacle Voltmeter Master Breaker Switch VOLTAGE SELECTOR ON SÉLECTEUR DE TENSION MARCHE MASTER BREAKER INTERRUPTEUR PRINCIPAL ON MARCHE LOW OIL Ground Terminal HUILE BAS OFF HPG4000 120V VOLTMETER ARRET VOLTMÈTRE ENGINE START DÉMARRAGE DU MOTEUR AC BREAKER OFF ARRET DC BREAKER SYSTEM FLOATING INTERRUPTEUR CA ON MARCHE 120V/ 240V ON MARCHE OFF ARRET OFF ARRET DISJONCTEUR CC SY
LABEL PLACEMENT 9
3.0 PRE-OPERATION INSPECTION 3.1 ENGINE OIL CHECK 1. Ensure the generator is on a level surface. 2. Inspect engine oil: • Take out the oil ller cap and clean the dipstick. • Check the oil level by reinserting the oil ller cap without rotating it. Remove the oil ller cap and examine the oil level. If the oil level is at or below the lower level, rell the oil to the upper limit mark. (10W30 Oil for all three models) • Reinsert the oil ller cap and tighten securely. (Refer to Fig. 3.0) Fig 3.
3.2 FUEL LEVEL CHECK: • • Check the fuel level by reading the gauge or removing the fuel tank cap to visually check the level. Refuel if level is too low. Tighten the fuel tank cap securely after lling (Refer to Fig. 3.1) Fig 3.1 Low High NOTICE When the oil level is low, the low oil light on the control panel will flash and the engine will automatically shut down. Then take off the oil dipstick to check the oil level.
3.3 CHECK THE AIR FILTER 1. Loosen the knob and remove the air filter cover. Remove the air filter element and observe for cleanliness. (Refer to Fig. 3.2) 2. Clean the air filter element with soap and water or solvent. Squeeze dry and then soak in clean engine oil. 3. Squeeze out all excess oil and reinstall. Replace the element if it is damage Fig 3.2 Filter cover Filter element Knob NOTE: Check the air filter using the maintenance schedule. Always inspect air filter before using the generator.
4.0 OPERATION 4.1 MOUNTING INSTRUCTIONS HPG4000 (Refer to Fig 4.1) 1. Attach the handle bar to the upper frame of the generator. Tighten the bolts (14) and nuts (7) to the upper frame of the generator. 2. Attach the two peg stands to the bottom of the frame of the generator. Tighten the two bolts (6) and two nuts (7) to the lower frame of the generator. 3. Place the two wheels (5) on the wheel axle (4) and then secure the wheels using the washer (8) and split pin (9) to the wheel axle (4). 4.
Parts List for HPG4000 Bolt M6 x 16 15 Anti-Sink Plate 1 HPG6500/HPG7500 (Refer to Fig 4.2) 1. Attach the handle bars to the middle of the generator frame where specied in (gure 4.2) Tighten the bolts (14) and nuts (7) to the upper frame of the generator. 2. Attach the two peg stands at the bottom of the frame of the generator. Tighten the two bolts (6) and two nuts (7) to the lower frame of the generator. 3.
Fig 4.
4.2 ELECTRIC START BATTERY CONNECTION (HPG7500 ONLY) 1. Connect the red cable with the positive terminal of the battery. Ensure the connection is secured by using the fastener at the battery terminal. Refer to Fig 4.3 2. Connect the black cable with the negative terminal of the battery. Ensure the connection is secured by using the fastner at the battery terminal. Refer to Fig 4.3 Fig 4.3 c NOTE: Be sure to connect the Electric Start Battery to the HPG7500 Generator set before operation.
Do not attempt to connect cables with the battery terminals while engine is running. NOTE: Disconnect the cables from the battery terminals while the HPG7500 generator set is in storage. Failure to do so may cause complete discharge. 4.3 STARTING THE GENERATOR SET GROUND TERMINAL (For HPG4000, HPG6500 and HPG7500) Before using generator, a ground wire must be connected to the ground terminal. Before using the ground terminal consult a qualied electrician.
Fig 4.5 Fig 4.6 4. For HPG4000, press the engine switch to the “ON” position. Refer to Fig. 4.7. For HPG6500, press the engine switch to the “ON” position. Refer to Fig. 4.7. For HPG7500, press the engine switch to “ON” position. Refer to Fig. 4.7 Fig 4.7 FOR HPG4000 (similar to HPG6500) FOR HPG7500 5. You may turn on the LED light by pressing the LIGHT switch in Fig 4.7 to ON position for the better view of the front panel.
NOTE: Do not leave LED lights ON for long periods of time as it may consume all of the battery power. 6. Grasp the recoil starter handle and pull it until the engine starts. Refer to Fig. 4.8 ineffective on the next startup. Fig 4.8 7. After the engine warms up, push the choke lever back to the OPEN position. 8. You may turn on the Idle-Control switch to the ON position to save fuel consumption, while low load is applied to the HPG7500 generator set.
2. Rotate the fuel valve to “ON” position (vertical position). Refer to Fig 4.9 Fig 4.9 Valve Lever OFF ON 3. If the engine is cold, pull the choke lever out to close the choke. Refer to Fig 4.10 Fig 4.10 Choke Open Close 4. Push the engine switch to ON position until started, but the start time cannot be more than 5 seconds. Otherwise the alternator may be damaged. Refer to Fig 4.7 NOTE: Do not try to electric start more than 3 times in one attempt. Failure to do so may damage the generator set. 5.
Idle-Control is not effective for use with appliances that require only momentary power. So it is better to leave the Idle-Control OFF if an appliance cycles ON and OFF frequently. 4.4 USING THE GENERATOR SET For HPG4000 1. Turn off the switches of the device before connecting to the generator. 2. Select the receptacles to be used by using the AC Voltage Selector. Refer to Fig. 4.11 Fig 4.11 3. Start the generator according to section 4.3. 4.
Fig 4.13 5. Turn the Master Breaker to ON and turn on the device. Refer to Fig. 4.14 Fig 4.14 For HPG6500/HPG7500: 1. Turn off the switches of the device before connecting to the generator. 2. Start the generator according to section 4.3 3. Insert the plug of the device into the receptacle based on the voltage requirement of the device. Refer to Fig. 4.
Fig 4.15 4. Lift the Master Breaker switch to ON position and turn on the device. Refer to Fig. 4.14 NOTE: To stop the engine in an emergency, turn the engine switch “OFF”. In order to maintain generator’s performance: • • Always connect the generator to the ground terminal to prevent electrical shock. Add the watt ratings of all the loads that the generator set will be powering at the same time. Make sure that total wattage will not exceed the generator rating.
NOTE: Using the generator in rain, snow, or in water can lead to electrical shock. Always keep your generator dry and away from any water sources. Perform this test monthly to insure proper operation. If used outdoors unprotected from the weather, make sure to test before each use. Test Button The test button should extend with a click. If the test button does not extend, take to an authorized GMC generator service center.
5.3 GENERAL INSPECTION 1. Look for fuel leaks around the fuel tank, fuel hose, fuel valve and carburetor. Close the fuel valve and repair leaks immediately. 2. Look and listen for exhaust leaks while the engine is running. Have all the leaks repaired before continuing operation. 3. Check for dirt and debris and clean as necessary 4. Check the engine oil level and add oil as necessary.
5.4) AIR FILTER SERVICE 1. Rotate the knob counterclockwise to release. 2. Lift the air cover to remove from the air unit. 3. Remove the foam element. Refer to Fig. 5.0 Fig 5.0 4. If the foam element is dirty, clean it in warm soapy water, rinse, and allow it to dry thoroughly, or clean in non-flammable solvent and allow to dry. 5. Drip the foam element in clean engine oil, then squeeze out all excess oil. The engine will smoke when started if too much oil is left in the filter. 6.
5.5 SEDIMENT CUP SERVICE 1. Rotate the fuel valve to “OFF” position. 2. Remove sediment cup and O ring. 3. Wash the cup with non-flammable solvent. 4. After fully dried, remount the parts. 5. Rotate the fuel valve to “ON” and check for leakage. Fig 5.2 5.6 CHANGING ENGINE OIL 1. Place the generator is placed on a flat, level surface. 2. Start engine and run until it gets warm. 3. Stop engine. 4. Place oil pan or other container underneath the generator for holding oil. 5.
CAUTION Used motor oil may cause skin cancer if repeatedly left in contact with the skin for pro longed periods. Wash your hands with soap and water as soon as possible after handling used oil. Fig 5.3 Oil Filler Cap Oil Drain Plug 5.7 SPARK PLUG SERVICE 1. Remove the spark plug cap. 2. Clean any dirt and debris from around the spark plug base. 3. Use a wrench to remove the spark plug. Refer to Fig. 5.4 Fig 5.4 4. Visually inspect the spark plug. Discard it if the insulator is cracked or chipped.
Fig 5.5 6. Install the correctly gapped spark plug back into the original position. 5.8 HANDLING & STORAGE Handling 1. Turn off the engine switch and the fuel valve when transporting the generator set. 2. Do not touch the generator until the fuel choke is in the OPEN position because the engine is warm. 3. Keep the generator at a level position in order to prevent spillage. Storage Before storing the generator set for an extended period: 1.
Fig 5.6 Disconnecting Electric Start Battery 1. Disconnect red cable from the positive battery terminal. 2. Disconnect black cable from the negative battery terminal. Refer to Fig 4.3 3. Store the battery in a dry place and recharge it once a month. Do not store the battery in an excessively warm or cold place. (for HPG7500 only) 6.0 TROUBLESHOOTING The following table is a troubleshooting guide for diagnosing the generator set.
No DC output No Output Display or No LED lights Tripped DC circuit breaker Disconnect battery, reset breaker and have battery tested for shorts Electric Start battery is not connected Connect Electric Start battery 31
7.0 SPECIFICATIONS GENERATOR HPG4000 Rat requenc Hz) Rat AC O Pow M AC O Pow 1-P Rat Pow Factor 60Hz 4.0 W) AC V 120/240 (V ) 1.0 Max DC Output Power (W) 100 Rated DC Voltage (V) 12 P, Single cylinder forced air cooling roke OHV 25 deg tilt Type Displacemen ENGINE 3.25 W) 3 208cc ) Ignition model Non-contac ransistor Starting model Recoil Start M O rpm) 4.
GENERATOR HPG7500 Rat requenc Hz) Rat A O Pow M A O Pow 1-P Rat Pow Factor 60Hz 6.75 W) 7.5 W) AC V 120/240 (V) 1.0 Max DC Output Power (W) 100 Rated DC Voltage (V) 12 P cooling Type ENGINE Displacemen 420cc ) 3 Non-contac ransistor Ig Star M cylinder forc roke Rec O rpm) F Star ctr 8.
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For HPG6500 35
For HPG7500 36 HPG Series User Manual
9.0 WARRANTY Canadian distribution of Hyundai portable generators are distributed in Canada by: Midland International 26 Rd. Unit #2 Toronto, Ontario M9W 5Z6 Canada This product is warranted to be free of defects in material and workmanship for two years from date of purchase. This warranty guarantees that any defective parts will be repaired or replaced at no cost, including diagnosis and replacement parts.
Warranty Claim Procedure: Warranty service must be performed by one of our authorized service dealers. If you feel your generator is malfunctioning due to a defect or misuse, simply contact our customer support center for technical advice, a warranty claim or general information. Do not return your generator to the place of purchase for repair. MIDLAND INTERNATIONAL INC. SHOULD BE CONTACTED TO PROVIDE A CASE NUMBER BEFORE WARRANTY WORK CAN BEGIN.
11.0 QUESTIONAIRE Please complete and mail the form below, or register online by visiting our website: www.hyundaipower.
HPG Series User Manual
Please Mail To: Or Register Online At: Midland International Inc. Rd. Unit 2. 26 Etobicoke, Ontario M9W 5Z6 Canada www.hyundaipower.
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HPG Series User Manual