Hyundai HY2000SI Workshop Manual
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Hyundai HY2000SI Workshop Manual

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HY2000SI/HY2000SEI WORKSHOP MANUAL
WESTERN TOOL DISTRIBUTORS
October, 2011
1

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Summary of Contents for Hyundai HY2000SI

  • Page 1 ® HY2000SI/HY2000SEI WORKSHOP MANUAL WESTERN TOOL DISTRIBUTORS October, 2011...
  • Page 2 Preface This manual covers the construction, function and servicing procedure of the HYUNDAI POWER PRODUCTS® HY2000SI/SEI generator, certificated by WTD. Careful observance of these instructions will result in better, safe service work. All information, illustrations, directions and specifications included in this publication are based on the latest product information available at the time of approval for printing.

  • Page 3: Table Of Contents

    CONTENTS Preface .................................2 CONTENTS..............................3 1. SPECIFICATIONS............................5 1.1 SPECIFICATIONS..........................5 1.2 CHARACTERISTICS..........................6 1.3 Wiring diagram............................7 2 Service Information ...........................8 2.1 The importance of proper servicing....................8 2.2 Important safety precautions ......................8 2.3 Service rules ............................9 2.4 Serial number location........................10 2.5 Engine maintenance standards......................10 2.6 Motor..............................

  • Page 4: Contents

    11. Exploded engine view ..........................57 12. Valve cover/ Rocker arm ........................60...

  • Page 5: Specifications

    1. SPECIFICATIONS 1.1 SPECIFICATIONS Dimensions and weights Model HY2000SI/SEI Overall Length 545mm Overall Width 290mm Overall Height 500mm Net Weight, with battery 27kg Engine Model HX125 Type 4-stroke,OVH, single cylinder, Gasoline engine Displacement 125cc Bore x stroke 52.4Χ57.8 mm Maximum horsepower 4.35 Hp...

  • Page 6: Specifications

    Self-excitation (Magnet type) Phase Single phase Rotating direction Clockwise (Viewed from the generator) Frequency regulation AC-DC-AC conversion (Inverter type) 1.2 CHARACTERISTICS Model HY2000SI/HY2000SEI Maximum output AC 2.2KVA Rated output AC 2.0KVA Rated output DC 100W Rated frequency 50HZ Rated voltage AC...

  • Page 9: Service Information

    2 Service Information 2.1 The importance of proper servicing Proper servicing is essential to the safety of the operator and the reliability of the engine. Any error or oversight made by the t echnician w hile servicing can easi ly result in faulty operation, damage to the engine or injury to the operator.

  • Page 10: Service Rules

    2.3 Service rules 1. Use genuine HYUNDAI POWER PRODUCTS ®-recommended parts and lubricants or their equivalents. Parts that do not meet HYUNDAI ® design specifications may damage the engine. 2. Always install new gaskets, O-rings, etc. when reassembling. 3. When tightening bolts or nuts, begin with larger-diameter or inner bolts first and tighten to the specified torque diagonally, unless a particular sequence is specified.

  • Page 11: Serial Number Location

    2.4 Serial number location The serial number can be found stamped on the engine block above the oil dipstick. It is visible when the maintenance panel is removed. Serial Number 2.5 Engine maintenance standards Item Standard(mm) Part Service limit Engine Maximum speed without load 5000±100rpm —...

  • Page 12: Motor

    2.05-2.35mm 1.9mm Width t (0.0807”~0.0925”) (0.0748”) Item Standard(mm) Part Service limit 15.006 －15.017mm 15.08mm Connecting rod Small end I.D (0.590”~0.591”) (0.594”) 0.10±0.02mm (0.0039” ± 0.0008”) Valve clearance 0.15±0.02mm (0.0059” ± 0.0008”) 4.975-4.99mm 4.92mm (0.1958”~0.1964”) (0.1937”) Valves Stem O.D. 4.955 —4.970 m m 4.90mm (0.1950”~0.1951”) (0.193”)

  • Page 13: Torque Values

    2.7 Torque values Tightening torque Item Specification Lbs-ft N·m Connection rod bolt Spark plug M10*1*13 9.6~11 13~15 M6*75 7.4-8.9 10-12 Crankcase cover M12*1.25 51.8-59.2 70-80 Flywheel nut M5 Bolt, nut 3.7~5.2 Standard torque M6 Blot, nut 6~7.4 8-10 M8 Bolt, nut 13.3~16.2 18-22 Note: Use standard torque values for fasteners that are not listed in this table.

  • Page 14: Trouble Shooting

    3. Trouble shooting 3.1 General symptoms and possible causes Fuel filter clogged Replace Fuel tank tube clogged Clean Fuel valve clogged Clean Carburetor faulty clean Check valve / Choke pod Inspect Engine does Ignition coil faulty Inspect not start or is Spark plug faulty Inspect hard starting...

  • Page 15: Difficult Cold Starting

    3.2 Difficult cold starting The choke on the HY2000SI operates automatically. When the unit is off, the choke will return to the closed position. In some cases, the choke may close too sl owly or open too fast. Both conditions can cause difficulty starting the unit.

  • Page 16: Hard Starting

    3.3 Hard starting No fuel Check the fuel level in the tank. Add fuel and restart the engine. Sufficient fuel Fuel not reached Loosen the drain screw and Add fuel and restart the engine. check whether fuel reached the carburetor. Good spark Check fuel filter, pump, fuel valve...

  • Page 17: Cylinder Compression Check

    3.3 Cylinder compression check 1. Remove the spark plug cap and spark plug. 2. Install a compression gauge in the spark plug hole. 3. Put the remote switch is on the OFF position. 4. Turn the ignition switch to the start position and measure the cylinder compression. Cylinder compression 65 psi (0.45Mpa) 800rpm Pressure...

  • Page 18: Ignition System

    3.4 Ignition system § Fill oil to the correct level. § Use A7RTC or equivalent spark plug. § Spark plug inspection § Don‟t pull the recoil starter or turn the ignition switch to start while touching the high tension wire. §...
  • Page 19 Measure the spark plug gap and perform the spark plug test. Standard clearance: 0.6-0.7mm (0.024”- 0.028”) No spark Good spark Perform the s park test agai n Replace the spark plug. using a new spark plug. No spark Remove the control panel. Good spark Replace the module.

  • Page 20: Engine Oil Level Is Low, But Engine Does Not Stop

    3.5 Engine oil level is low, but engine does not stop. Drain out oil completely, disconnect the oil Check and repair all wire No continuity sensor wire harness, and check the connections. Replace the continuity between black wire and the oil level alarm chassis ground.

  • Page 21: Engine Speed Can"T Increase Or Unstable (Choke Is At The Correct Position)

    3.7 Engine speed can’t increase or unstable (choke is at the correct position) Blocked Check the air filter element for blockage. Clear the air filter element. Not blocked Blocked Inspect spark arrestor for carbon build up. Remove and clean carbon deposits.

  • Page 22: Engine Speed Doesn"T Increase With Economy System "On" And A Load Connected

    3.9 E ngine speed doesn’t inc rease with economy system “ON” and a load connected. Perform the generator Abnormal Check the AC output. troubleshooting following the instruction of “No or low AC output”. Normal Abnormal Check the throttle control motor. Replace the throttle control motor.

  • Page 23: Measuring Stator Output Voltage While Running

    3.11 Measuring stator output voltage while running. Inverter 6-Pin Stator Receptacle 6-Pin Stator Connector White Sub Windings 3 & 6 Black Phase Wires, 1, 2 & 4 1. Unplug the connector from the inverter and start the engine, check voltage between pins 1 & 4, between pins 2 &...

  • Page 24: No Dc Output At Receptacle

    3.12 No DC output at receptacle. Abnormal Perform the throttle control system Is the engine speed normal? test. Normal Abnormal Check the DC circuit breaker. Reset DC circuit breaker. Normal Abnormal Check the wire harness and all Check the DC output. connections.

  • Page 25: Voltage Regulator

    3.14 Voltage regulator Control Panel Inverter Harness Chassis Battery Ground Terminal Ignition Switch Voltage Starter Regulator Solenoid Stator Starter Solenoid Chassis Ground Terminal...

  • Page 26: Starter Motor Doesn"T Run

    3.15 Starter motor doesn’t run. Abnormal Measure battery voltage. Charge battery. Normal Abnormal Check the 20A fuse at battery. Replace 20A fuse. Normal Abnormal Check the ignition switch. Replace ignition switch. Normal Abnormal Check the starter relay. Replace the starter relay. Normal Abnormal Replace the starter motor...

  • Page 27: No Output When Operating In Parallel

    Two separate HY2000SI/SEI models can run in parallel to increase the total output to a maximum load of 4200 W (Rated output, 5200 W). § You can also run a HY2000SI and a HY2000SEI in parallel. The maximum output will be 4200 W (Rated output, 4000 W). §...

  • Page 28: Parallel Operating Procedure

    § The required output of the electrical appliance cannot exceed the rated output of the generators. The special parallel cable for the HY2000SI and HY2000SEI is only applicable to the parallel operation of two HYUNDAI generators. It cannot be used for paralleling three or more generators or running two different brands of generators.
  • Page 29 § To prevent electrical shock from faulty appliances, the parallel kit should be grounded. Connect a length of heavy cable between the parallel ground terminal and an external ground source. 1. During normal operating conditions, the output indicator lights (Green) will remain illuminated. 2.

  • Page 30: Troubleshooting Parallel Operation

    3.18 Troubleshooting Parallel Operation: Problem Condition Cause Correction Flashing The red overload light on one of The load (Wattage) Remove all loads from the overload the generators is flashing slowly. has exceeded the parallel panel and the light. There are no indicator lights on capacity of one or generators and press the green the other generator or parallel...
  • Page 31 3.19 Troubleshooting Parallel Operation (Cont.) Problem Condition Cause Correction There is no AC output Loose or disconnected Remove all loads from the parallel panel indicator from either of the power cord between the and the generators. lights (Red generators or parallel parallel kit and parallel or Green) panel.

  • Page 32: Maintenance Schedule

    (1) For commercial use, operation hours are determined by proper maintenance. (2) Service more frequently when operating in dusty areas, every 10 hrs or every day. (3) Service by HYUNDAI authorized agency, unless correct tools or professional specialist is available. Do service according to the manual.

  • Page 33: Checking The Oil Level

    4.2 Checking the oil level. Stop the engine and check the oil level, be sure to put the engine on a flat floor when checking. 1. Loosen the screw of the maintenance cover and remove the cover. 2. Remove the oil filler cap and check for the oil level. 3.

  • Page 34: Checking For The Low Oil Sensor

    § Please dispose of used motor oil in a manner that is compatible with the environment and local disposal regulations. Do not throw it in the trash or pour it on the ground. 4.4 Checking for the low oil sensor 1.
  • Page 35 4.5 Air Filter Inspection/Cleaning: 1. Loosen the panel screw and remove the side maintenance panel. 2. Remove the three air filter retaining screws. Remove the air cleaner cover and check the element. Clean or replace the element if necessary. 3. Wash the element in a non-flammable or high flash point solvent and dry it thoroughly. 4.
  • Page 36 4.6 Spark plug Inspection/Cleaning: 1. Remove the spark plug cap and remove the spark plug. 2. Remove carbon or other deposits with a plug cleaner or stiff ire brush. Check the sealing washer for damage. 3. Measure the plug resistance; replace the spark plug if the measurement is not within the value shown.
  • Page 37 4.7 Valve clearance § Valve clearance inspection and adjustment must be performed with the engine cold. Inspection/Adjustment: 1. Disconnect the battery. 2. Drain all fuel from the tank and carburetor. 3. Remove front and rear panels. 4. Remove the left and right covers. 5.
  • Page 38 Insert a feeler gauge between the rocker arm and the valve and measure the valve clearance. 0.10+/- 0.002mm (0.0039” ± 0.0008”) Valve clearance 0.15 +/- 0.002mm (0.0059” ± 0.0008”) 12. If adjustment is necessary, proceed as follows. a. Loosen t he a djusting screw lock nut and a djust the v alve clearance by turning t he adjusting screw in or out.

  • Page 39: Evaporation Control

    4.8 Fuel tank § Gasoline is highly flammable and explosive. You can be burned or seriously injured w hen handling fuel. Keep heat, sparks, and flame away. Wipe up spills immediately. Cleaning: 1. Disconnect the battery. 2. Drain all fuel from the tank and carburetor. 3.

  • Page 40: Fuel Pump, Primer Bulb

    4.10 Fuel pump, primer bulb § Gasoline is highly flammable and explosive. You can be burned or seriously injured w hen handling fuel. Keep heat, sparks, and flame away. Wipe up spills immediately. 1. Disconnect the battery. 2. Remove front and rear panel. 3.

  • Page 41: Muffler System

    5 Muffler system 5.1 Spark arrestor § Do the performance after engine has cooled completely. 1. Remove the four M6 screws and remove the muffler grill. 2. Remove the two M4 screws holding the spark arrester to the muffler. 3. Use a stiff wire brush to remove carbon deposits from the spark arrester screen. 4.
  • Page 42 § Muffler removal/installation must be performed with the engine cold. 5.2 Muffler Disassembly/Reassembly 1. Disconnect the battery. 2. Drain all fuel from the tank and carburetor. 3. Remove front and rear panel. 4. Remove the left and right cover 5. Remove fuel tank. 6.

  • Page 43: Exhaust Tube, Secondary Air Valve

    5.3 Exhaust tube, secondary air valve Disassembly/Reassembly 1. Disconnect the battery. 2. Remove front and rear panel. 3. Remove right cover Secondary Air Valve...

  • Page 44: Carburetor

    6. Carburetor 6.1 Disassembly/Installation of Carburetor § Turn fuel lever to the “OFF” position. § Keep heat, flame and sparks away. 1. Disconnect battery. 2. Remove maintenance panel. 3. Disconnect the right vent hose from the carbon canister. 4. Drain fuel from carburetor. 5.
  • Page 45 6.2 Disassembly/Installation of Step motor 步进电机机盖 步进电机 Step motor 步进电机座 Step motor base 拔叉弹簧 Fork spring 拔叉 拆卸： Disassembly: Fork 拆卸时用手捏牢， Carefully remove 以防弹簧丢失。 the spring and fork 拔叉 Fork 油门杆 from the throttle Throttle level lever. 拔叉弹簧 Fork spring 怠速调整限位帽...
  • Page 46 6.3 Disassembly/Installation of Carburetor Choke lever 阻风门杆 Fork 拨叉 Fork spring 拨叉弹簧 Choke plate 阻风门片 Idle adjusting cap 怠速调整限位帽 Mixed ratio adjusting Carburetor block screw, 本体 混合比调节螺丝 (Not adjustable on 出厂前位置已确 CARB units) 定， 不可调节 Emulsifier tube Installation: clear the Needle seat foreign matters with 针座...

  • Page 47: Step Motor

    6.4 Step motor Make sure to check the step motor connection on the inverter for any debris, damaged or bent pins Measure the resistance of the step motor lead-out wire. Replace the step motor if the resistance exceeds the ranges shown below. 1-blue ~ 2-white ：50~55Ω...

  • Page 48: Automatic Choke Inspection/Adjustment

    6.5 Automatic choke inspection/adjustment. The choke on the HY2000SI/SEI operates automatically. When the unit is off, the choke will return to the closed position 1. The automatic choke consists of the backpressure check valve and the vacuum pot, figure 1.

  • Page 49: Control Panel

    7. Control panel 7.1 Disassembly/Installation Remove six M4 panel screws. Parallel Power Socket Parallel Signal Ignition Port Switch Indicator Module Module Cover Button Guard Stop / Reset Buttons 120V~20A Circuit Breaker DC Battery Charge DC Circuit Receptacle 120V~20A Breaker Duplex Covers Economy / Remote Switches...

  • Page 50: Outer Generator Housing

    8. Outer generator housing 8.1 Disassembly and installation of housing case Spark Plug Access Exhaust Grill Maintenance Cover Inverter Right Case Control Panel Panel Frame Left Case Fuel Pump Primmer Bulb Fuel Lever Fuel Valve Battery Access Cover...

  • Page 51: Recoil Starter / Electric Starter / Ignition Coil

    9. Recoil starter / Electric Starter / Ignition coil Caution ■ D rain all gasoline from the fuel tank before disassembly. ■ K ee p the unit away from all hea t, flame and spark s . 9.1 Recoil starter/Disassembly/Reassembly 1.

  • Page 52: Starter Motor

    9.2 Starter motor ● Disassembly 1. Disconnect the battery. 2. Remove front and rear panels. 3. Remove the left and right covers 4. Using and 8mm socket remove 2-mounting bolt. 5. Remove the starter and the cable. Starter Relay Cable Screw Mounting Bolts...

  • Page 53: Starter Solenoid

    9.3 Starter solenoid 1. Using a volt ohm meter, check the resistances of the electromagnetic coil of the starter relay by connecting the red positive lead to the ¼” spade and the black negative lead to the metal body of the relay.
  • Page 54 9.3 Ignition coil Inspection 1. Remove the control panel and locate the 2-pin primary coil plug with a Blue and Black wire and unplug it from the control panel. 2. Attach the two leads of tester to the Blue and Black wires and measure the primary resistance of the ignition coil.

  • Page 55: Ignition Coil/Disassembly

    9.4 Ignition coil/Disassembly 1. Disconnect the battery. 2. Remove front and rear panel. 3. Remove the left and right cover 4. Remove the fuel tank and the inverter. 5. Remove the inlet fan cover. 9.5 Adjustment 1. Adjust the clearance between the ignition coil and the outer magnet trigger of the rotor. 2.

  • Page 56: Rotor/Stator Disassembly / Reassembly

    10. Rotor/Stator disassembly / reassembly 10.1 Disassembly/Reassembly 1. Remove the following parts: ¾ Front cover, control panel. ¾ Rear cover. ¾ Right/left side covers. ¾ Fuel tank. ¾ Battery box. ¾ Inverter. ¾ Fan cover ¾ Starter cup and fan ¾...

  • Page 57: Stator Inspection

    10.2 Stator Inspection (1) DC charging winding Measure the resistance between the two blue terminals. Blue-Blue Resistance 0.045~0.070 Ω (3) Sub winding Measure the resistance between the two sub winding terminals. White-White Resistance 0.100~0.160 Ω (4) Main winding Measure the resistance between each of the main winding terminals. Black-Black-Black Resistance 0.250~0.350...

  • Page 58: Exploded Engine View

    11. Exploded engine view...
  • Page 59 152 Engine Item No. Description Mfg No Stock No. M6 x 75 hex screw 03050611 Front engine cover 76115 Front seal 040906-07 69700 M8 nut 03060115 69709 Chain for oil pump 09070116 69710 Chain wheel for oil pump 09070117 69712 M6 x 25 bolt 03050241 69349...
  • Page 60 152 Engine Item No. Description Mfg No Stock No. Piston 09070101 Cylinder gasket 09070165 69695 Locating bushing, head 04030264 M8 x 195 threaded stud 03050603 M8 x 185 threaded stud 03050601 Cylinder sleeve 09070105 Locating bushing, head 04030264 Head gasket 09070107 69685 Intake valve...

  • Page 61: Valve Cover/ Rocker Arm

    12. Valve cover/ Rocker arm 12.1 Disassembly/ Reassembly Remove the four bolts and valve cover. 1. Turn the rotor to set the piston at top dead center of the compression stroke. 2. The timing mark of camshaft should be vertical to the cylinder head seal, check whether the inlet and exhaust valve are closed.
  • Page 62 12.2 Rocker Arm Inspection ● Rocker arm outer diameter Standard Service limit 9.96—9.97mm 9.953mm (0.392-0.393”) (0.391”) ● Rocker arm inner diameter of inlet/exhaust valve Standard Service limit 10.000-10.015mm 10.040mm (0.3936-0.3942”) (0.3952”)

  • Page 63: Cam And Cylinder Head Removal / Reassembly

    12.3 Cam and cylinder head removal / Reassembly 1. Turn the rotor to set the piston at top dead center of the compression stroke. 2. The timing mark of camshaft should be vertical to the cylinder head seal. Make sure the inlet and exhaust valve are closed.
  • Page 64 7. While holding the safety wire that is attached to the timing chain, carefully remove the cylinder head and gasket. Timing Chain Head Gasket Reassembly: 8. Replace the head gasket. 9. Follow the reverse procedure to reassemble. Caution § Make sure that the piston is at top dead center which can also be confirmed by locating the crank shaft keyway in the vertical (Upright) position.
  • Page 65 Reinstalling the timing chain tensioner: 10. Remove the adjustment cover screw and „O‟ -ring. 11. Replace gasket. 12. Using a s mall flat blade screw driver rotate t he s pring loaded adjustment screw clockwise t o retract the plunger. 13.

  • Page 66: Inspection, Valves And Valve Springs

    12.4 Inspection, valves and valve springs ● Free length of valve spring Spring Standard Service limit Small 35.5mm (1.397”) 31.1mm (1.224”) Large 32.8mm (1.291”) 33.8mm (1.330”) ● Valve seat width Standard Service limit 1.0mm (0.039”) 2.0mm (0.079”) ● Valve stem outer diameter Standard Service limit 4.975 - 4.99mm (0.1958-0.1964”)
  • Page 67 12.5 Piston/Connection rod Assembly of piston ring Caution 1 r ing ● Make sure the rings are installed with the manufacturer‟s label ? ? ? ? ( ? ? 2 ring ? ? ? ? ( ? ? Oil ring ●...
  • Page 68 ● Cylinder inner diameter Standard Service limit 52.4000-52.420mm (2.0630-2.0638”) 52.505mm (2.0671”) ● Piston skirt outer diameter Standard Service limit 52.360-52.380mm (2.061-2.062”) 52.25mm (2.057”) Piston pin clip 10m m ● Side clearance of piston ring Standard Service limit 0.02-0.06mm (0.0008-0.0024”) 0.15mm (0.0059”) 1 and 2 Ring 0.03-0.18mm (0.001-0.007”) 0.24mm (0.009”)
  • Page 69 ● Piston ring end clearance Locate the piston ring into cylinder with piston top, and measure the piston end clearance. Standard Service limit 0.15-0.25mm (0.0059-0.0098”) 1.0mm (0.039”) 1 and 2 Ring 0.20-0.50mm (0.0078-0.0196”) 1.0mm (0.039”) Oil Rings ● Piston ring height Standard Service limit 0.97-0.99mm (0.0381-0.0389”)
  • Page 70 ● Piston pin outer diameter Standard Service limit 14.994-15.008mm (0.5903-0.5905”) 14.95mm (0.5925”) ● Piston pin hole inner diameter Standard Service limit 15.002-15.008mm (0.5907-0.5908”) 15.05mm (0.5925”) ● Connection rod small end inner diameter Standard Service limit 15.006-15.017mm (0.590-0.5991”) 15.08mm (0.594”)

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