KDE5000TA - American RV Company
Contents
1. KDE5000TA iagram m REM Za u um px gen ic wiring 2 TA type electr ye Wd Y Xvd lv Xvaaly lt lt gt 0 olz Ppejuoo 5 0 MOT V 0 90 Enjd asn4 yoz 3 0 06 90 asna ebpuq Ansy Bupum Buidures Buneleuag Bupuim uonelox3 Bupumans Bupuim Jojeseuab joeuM Guibreyo rewojsng Jejsnipe abeyon onewony S LAM ed GLA2. POWER OPERATION MANUAL KIPOR WUXI KIPOR POWER CO LTD Address Beside Jingyi Rd Third stage Development Section of Wangzhuang Industry Area Wuxi High 8 DIESEL New Technology Industry Development Zone TEL 0086 510 85200888 GENERATOR FAX 0086 510 85200999 E MAIL kipor kipor com Coast Distribution System Inc KDESODOE KDESOOOTA Email kiporcare coastdist com Phone 877 544 4449 Version 5 Printing date 28 10 2006 Coast MADE IN CHINA Thank you for purchasing a Kipor generator through the Coast Distribution System This manual covers the operation and preventive maintenance of the KDE5000E and KDESOOOTA generator sets This manual is primarily concerned with the generator specifications function troubleshooting and repair There is a separate manual to cover the KM186FA engine 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 If a problem should arise or if you have any questions about the generator consult an authorized Kipor service center Our generators are designed to give safe and dependable service if operated according to instructions Read and understand the operation manual before operating the generator Failure to do so could result in personal injury or equipment damage Several preventive maintenance pr
3. 1 Drain out the fuel from the fuel tank Remove the small screw of the fuel cock and pull os a out the filter from the filler port EN Im 3 Wash the filter thoroughly with diesel fuel 1 mall am Loosen the fastening nut bottom cover and delivery discs for cleaning any deposits 7 5 Check the injection nozzle and fuel injection pump Consult the service manual 7 6 Check the generating set carbon brush and slip ring Consult the service manual 8 SHORT TERM STORAGE AND EXERCISE 1 Add oil to max level without overfilling 2 Fill tank with fresh diesel fuel Treat with a quality diesel fuel conditioner 3 Exercise the generator every 30 days Run it with at least a 50 load 2500 watts for 30 minutes This will serve to lubricate the injection pump and bake out any moisture that has accumulated in the generator windings 9 LONG TERM STORAGE If storing the generator for periods exceeding 30 ES AR 4 te dv y Oil fillercapiDistick days perform the following steps 1 Operate the engine for about 3 minutes and then stop oe 2 Drain the engine oil while the engine is u Dra e A warm and fill with fresh oil 3 Remove the screw plug on the cylinder head cover and add 2cc of clean engine oil then replace the plug 4 MRecoil starting Push the decompression lever down Non compression position and hold it while you pull the recoil starter
4. 2 3 times Do not start the engine Electric starting Turn the engine 2 3 seconds with the decompression lever set at the non compression position and the starting key at the START position Do not start the engine 5 Wipe off any oil and dirt from the engine and store in a dry place 10 TROUBLESHOOTING AND REPAIRS 10 1 The diesel engine will not start or is difficult to start Fault Remedy Deteriorated diesel fuel in the tank Drain the tank and refuel with fresh diesel fuel Fuel filter is clogged Clean or replace fuel filter Cock in the Start position Fuel is not Turn it to the START position The governor lever of the engine throttle is not in the start position Switch to the start position Oil filter is clogged causing low oil pressure switch to activate Clean or replace oil filter Low oil pressure switch failure Check wiring and replace switch as necessary Air in the fuel lines often occurs after running out of fuel Consult the service manual for bleeding procedure Valves out of adjustment Check valve adjustment and reset as necessary refer to service manual Insufficient battery voltage to energize starter and or fuel solenoid valve Check battery state and terminals and cables 10 2 Engine speed is unstable too high or too low Fault Remedy Engine governor spring is defective Replace governor spring
5. 39 2 83 86x72 Displacement cu in cc 25 5 418 Cooling system Forced air cooled system Lubricating system Pressure splash Lube oil capacity qt L 1 45 1 65 Starting system recoil electric electric Fuel Diesel Fuel capacity gal L 3 96 15 4 23 16 Low oil pressure alarm with 2 IDENTIFICATION 2 1 Component Location KDE5000E Fuel tank Air cleaner Starting handle Recoil starter Engine speed lever drain plug ON filler cap Dipstick Fuel filler cap 2 2 Component Location KDE5000TA Engine starter switch AC output Low oil pressure Fuel filler cap Lifting eye warning lamp outlet Outlet for cooling air 2 3 Control panel KGE5000E OIL ALERT WARNING LAMP VOLTMETER START SWITCH e 6 CIRCUIT BREAKERS 20 AMP 120VAC GROUNDING STUD DUPLEX 30 AMP 120VAC RECEPTACLE 30 AMP 120 240VAC RECEPTACLE KGE5000TA START SWITCH CIRCUIT BREAKERS CONTROL SCREEN pi DISPLAY PANEL e e P O1 Low Gil Pressure P 02 Under Cwer Frequency 20A120VAC DUPLEX RECEPTACLE P 03 Under Gver Voltage P 04 Current Overload 06 Bat Charge Fail P 06 Hi Engine Temp 0 E PANEL FUSE KIPOR e FUSE BASE bauch So GROUN
6. Engine serial number and proof of purchase is required EXCLUSIONS THIS WARRANTY DOES EXTEND TO PARTS AFFECTED OR DAMAGED BY ACCIDENT AND OR COLLISION NORMAL WEAR FUEL CONTAMINATION USE IN AN APPLICATION FOR WHICH THE PRODUCT WAS NOT DESIGNED OR ANY OTHER MISUSE NEGLECT INCORPORATION OR USE UNSUITABLE ATTACHMENTS OR PARTS UNAUTHORIZED ALTERATION OR ANY CAUSES OTHER THAN DEFECTS IN MATERIAL OR WORKMANSHIP OF THE PRODUCT THIS WARRANTY DOES NOT EXTEND TO NORMAL MAINTENANCE ITEMS SUCH AS SPARK PLUGS AND FILTERS DISCLAIMER OF CONSEQUENTIAL DAMAGE AND LIMITATION OF IMPLIED WARRANTIES COAST DISTRIBUTION DENIES ANY RESPONSIBILITY FOR LOSS OF TIME OR USE OF THE PRODUCT TRANSPORTATION COMMERCIAL 1055 OR ANY OTHER INCIDENTAL OR CONSEQUENTIAL DAMAGE ANY IMPLIED WARRANTIES ARE LIMITED TO THE DURATION OF THIS WRITTEN LIMITED WARRANTY Some states do not allow limitations on how long an implied warranty lasts and or do not allow the exclusion or limitation of incidental or consequential damages Therefore the above exclusions and limitations may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state 24
7. Item Daily First 20 Hours 100 hours or three months 500 hours or six months 1000 hours of every year Check cables Battery and Check Fuel Level Check Oil Level Replace engine oil Check Air Filter Element Replace air cleaner element Clean oil filter replace if necessary Clean fuel filter Replace Fuel Filter Check fuel pump injection Check fuel injector Check fuel lines e replace if necessary Adjust valve clearance Check carbon brush and slip rings service more frequently in dirty or dusty conditions Note e indicates special tools and or knowledge required Contact an authorized Kipor service center as necessary 16 7 1 Changing the engine oil Remove the oil filler cap Remove the drain plug tlercap Distick 2 and drain the old oil while the engine is still warm EM m yf The plug is located on the bottom of the cylinder block Tighten the drain plug and refill with the recommended oil 7 2 Clean the engine oil filter Every 6 months or 500 hours 7 3 Replace the air cleaner element Do not clean the air cleaner element with detergent 7 4 Clean and replace fuel filter The fuel oil filter also has to be cleaned regularly to insure maximum engine output Clean Every 6 months or 500 hours Replace Every year or 1000 hours
8. outage and when utility power is restored the generator may explode burn or cause fires in the building s electrical system WARNING 1 TO PREVENT FIRE Never add fuel to the fuel tank while the engine is running Wipe off any overflowed diesel fuel with a clean cloth Keep explosives and other flammable products away from the generator set m To prevent fire and to provide adequate ventilation keep the generator at least three feet one meter away from buildings and other equipment during operation Operate the generating set on a level surface Do not put the generating set indoors while the engine is hot 2 TO PREVENT EXHAUST INHALATION Exhaust gas contains poisonous carbon monoxide which is harmful to your health possibly fatal Never use the generating set in confined spaces or poorly ventilated areas 3 AVOID BURN INJURIES The muffler and the engine body are very hot while the engine is running or just after running Do not touch these parts to prevent from being severely burned 4 ELECTRIC SHOCKS To avoid electric shocks or short circuits do not touch the generating set when your hands are wet This generating set is not waterproof so it should not be used in a place exposed to rain snow or water spray Use of the generator in a wet place can cause short circuits and electrical shocks during operation m The generating set should be grounded to prevent electrical shocks from faulty appliances
9. period The first 20 hours are considered a break in period for the engine Please observe the following instructions m Warm up the engine 5 minutes upon the initial start Run the engine with no load until the engine becomes warm m Avoid applying any heavy loads during the break in period No more than a 5096 load 2500 watts is recommended m Replace the engine oil while the engine is warm after the initial 20 hour run time 4 STARTING THE GENERATOR WARNING m Do not plug in any tools or appliances into the generator before starting 4 1 Recoil starting KDE5000E Start the engine according to the following procedures 1 Open the fuel cock 2 Set the engine speed lever at the RUN position 3 Pull out the recoil starter handle m Pull out the handle until you feel the resistance then return it back to the initial position m Press down the decompression lever It will return automatically when the recoil starter is pulled m Firmly pull the recoil starter handle CAUTION Do not allow the handle grip to snap back against the engine Return it gently to prevent damage to the starter mechanism When the engine is difficult to start in cold weather remove the screw plug from the cylinder head cover and add 2cc engine oil Be sure to replace the plug to prevent moisture and dirt from entering the engine The use of aerosol starting fluids is prohibited Severe piston d
10. Connect a length of heavy wire between the generator set ground terminal on the control panel and an external ground source m Do not hook up tools or other appliances to the generator before it has been started If equipment is plugged in and the circuit breakers on the generator starting motion may cause sudden movements of the equipment and possibly result in injuries Be sure to disconnect any tool or appliance from the generator prior to starting CAUTION m Most appliance motors require more than their rated current for start up m Do not exceed the specified current limit of any receptacle m Do not connect the generating set to a household circuit This could cause damage to the generating set and to electrical appliances in the house 5 WHEN CHARGING THE BATTERY Your generator is equipped with a maintenance free battery Leakage of battery electrolyte is possible if the case is penetrated Battery electrolyte contains sulfuric acid Protect your eyes skin and clothing In case of contact flush thoroughly with water and get prompt medical attention Batteries generate hydrogen gas which can be highly explosive Do not smoke or allow flames or sparks near a battery at any time Charge the battery only in a well ventilated area 5 65 1 2 Component Identification a 2 3 Pre
11. DING STUD 30A 120VAC RECEPTACLE 30A 120 240VAC RECEPTACLE 2 4 KDE5000TA Digital Display Panel Operation POWER VA RUNTIME BAT VOLT o CODE LIST 01 Low 011 Pressure P 02 Under Over Frequency 03 Under Over Voltage P 04 Current Overload P 05 Bat KI w k D The panel is designed to give the operator precise information regarding generator operation and current loads Additionally should the generator experience a condition necessitating shutdown a fault code appears on the screen When running the green RUN light should be illuminated Press the function FUNC button to change the display A green light should appear above the digital readout to indicate the current function You have a choice of voltage 120 or 240 power VA Frequency HZ total runtime in hours and starting battery voltage Fault codes are explained in the troubleshooting section 2 5 Serial number and bar code identification and location The generator serial number identifies your particular unit and is important when ordering parts and accessories The bar code is used by your dealer and Coast Distribution for warranty administration The serial number for the KDE5000TA is located on the air inlet plate to the left of the diesel injection pump The serial number for the KGE5000E can be found on a stainless steel shroud surroundin
12. DO p BA ON ml L mes vo fi mm i meg z ver men _ mi 58 d 591 dA ueauawy sejot Ino Al Ir N SLAY 3009 Deo fel Ol mi enaena Zt uz Je ww er am s em er m Ja m ei vanw s ful S e amp Lan twon asng 9 Charge winding indino yes 2 uas Control panel Acl aides oy Bau 4 enig 9 OAM abue SOAY YARD NDA Jojou Jaueis Low oil switch Flywheel generator O HAH Pay adug fudwasyoun SIAM 39918 ica geseyg fujdues wany 3088609939 ESSEN 19 Bugdiues Bulpunal5 S OAH MOBA SOAS OPA Sony Yoltage sampling Dr usag jusung Otan ann 2 SUM 3 o c 140 pay 189 e OPPE Iejsueniu uno 23 12 WARRANTY Kipor Power Equipment Limited Warranty LENGTH OF WARRANTY Generators and or batteries that are supplied with applicable products as standard original equipment are covered by this warranty from the date of original retail purchase for a period of 2 years for residential use and 1 year for commercial applications Units used in rental fleets or as demonstration models will be considered com
13. Valves out of adjustment Check valve adjustment and reset as necessary refer to service manual Governor out of adjustment Adjust governor refer to service manual 10 3No AC output Fault Remedy Circuit Breakers closed Open circuit breakers Receptacle is defective Check wiring and check or replace receptacle 10 4 No display KDE5000TA Fault Remedy No 12V power supply Check control panel fuse Check for 12V DC to panel check wiring continuity 10 5 KDESOOOTA Digital Panel Faults Fault Possible Cause and Remedy 01 Low Oil Pressure 1 Low oil level check and refill as necessary 2 Clogged oil filter remove and clean replace 3 Bad oil switch test per service manual P 02 Over Under Frequency Consult service manual P 03 Over Under Voltage Consult service manual P 04 Current Overload 1 Reduce the number of loads on the generator and restart 2 Check the appliance or tool for proper operation P 05 Battery Charge Failure 1 Check battery and battery terminals and connections 2 Test charge adjuster per service manual P 06 High Engine Temp Not applicable to this generator 11 WIRING DIAGRAM 1 E type electric wiring diagram KDE5000E
14. amage result 4 2 Electric starting 1 Starting The preparations for electric starting are the same as for the recoil starting m Open the fuel cock Set the engine speed lever at the RUN position Turn the starting key clockwise to START position Remove your hand from the key as soon as the engine starts If the starting motor does not start after 10 seconds wait 15 seconds before starting it again 5 OPERATING THE GENERATOR 5 1 Operate the generator Warm up the engine without load for three minutes 5 2 Check while running 1 Abnormal sound or vibration 2 Engine misfiring or rough running 3 Heavy exhaust smoke especially blue or black If you notice any of the above mentioned conditions stop the engine and correct the problems before running the generator 5 3 AC application 1 After switching on the circuit beakers observe the voltmeter on the control panel or digital display Do not operate the generator if a reading other than 120 5 volts is observed The KDE5000TA will automatically shutdown on an over or under voltage 2 Connect the equipment to the generating set in order i e the appliances with the highest current load first CAUTION overloading of the circuit trips an circuit breaker reduce the electrical load on the circuit and wait a few minutes before resuming operation 3 The generator is designed to permit simultaneous 120 and 240 vol
15. g the alternator to the right of the engine The bar code is found in three locations on the generator on the packing crate or carton and on the inside cover of the operator s manual 3 PREPARATION FOR STARTING 3 1 Selection and handling of diesel fuel m Selection of diesel fuel Diesel 2 is the most suitable for the engine A Cetane rating of 40 42 is recommended at temperatures above 32 F 0 C A Cetane rating of 45 is recommended at temperatures below 32 F 0 C Winter fuels are often blended by refineries so for optimum performance don t use stored winter fuel in warmer weather m Keep dust and water out of the fuel When filling the fuel tank from drums make sure that no dust or water is mixed in the fuel Serious fuel injection pump and injector problems will result m Do not overfill Overfilling is very dangerous Do not fill the tank beyond the top of the red plug inside the fuel strainer m Below 15 degrees F wax crystals begin to form in diesel fuel These will clog the fuel filter and stop the engine as the temperature drops toward 0 F Any good winter fuel conditioner for diesel fuel will keep the fuel moving to at least 20 degrees Follow the manufacturer s instructions WARNING m Refuel in a well ventilated area with the engine stopped m Do not smoke or allow flames or sparks in the area where the engine is refueled or where the fuel oil stored m Do not overfill the tank make sure
16. icking accelerated wear of the cylinder liner bearings and other moving parts increases significantly and the life of the generator is shortened KIPOR recommenas an API classification of CD CF 2 CG 4 SJ Choose the applicable viscosity oil according to local ambient tem peratu re SAE Viscosity Grades Single Viscosity Multi T viscosity Ta AMBIENT TEMPERATURE 3 3 Connect the Battery To connect the battery first connect the positive red cable to the positive post of the battery Use the fasteners provided and ensure the connection is secure Next connect the negative black cable securely to the negative battery terminal Use the reverse order when disconnecting the battery 3 4 Service the air cleaner 1 Unscrew the wing nut remove the air cleaner cover and take out the element UM KDE5000TA air cleaner can be accessed by 9 275 removing the panel on the left side of the set s CAUTION m Do not wash the element with detergent m Replace the element when dirty or the paper is torn m Never run the generating set without the element or rapid engine wear will result 2 Reattach the air cleaner cover and tighten the wing securely 3 5 Check the generating set 1 Tum off all circuit breakers and disconnect any loads nn Aw DOUR USE ONLY WARNING m he generator should be grounded to prevent electric shocks Ground Lug 3 6 Break in
17. mercial usage The warranty coverage is continual from the original date of purchase and does not restart upon the replacement of any part or complete unit Individual parts replaced at any point during the warranty period are only eligible for warranty coverage for the balance of the original warranty period ELIGIBILITY To be eligible for warranty service the product must be purchased in North America from an authorized Kipor dealer This warranty applies to the original retail purchaser only and is not transferable Proof of purchase is required Goods exported from North America as well as goods sold at auction are excluded from warranty coverage COVERAGE Parts labor and regular shipping costs will be covered by Coast Distribution for any failure that is proven to be a failure in material or workmanship under normal use during the applicable warranty time period Coast Distribution reserves the right to repair or replace these parts at its option Coast Distribution may request defective parts to be returned Anything replaced under warranty becomes the property of Coast Distribution TO OBTAIN WARRANTY SERVICE Contact any authorized dealer or contact our national customer service center at Phone 1 877 544 4449 Fax 1 800 263 0280 E mail kiporcare coastdist com If contacting us by fax or e mail be sure to include a description of the problem as well as all return contact info such as address phone number fax number e mail etc
18. ocedures require background knowledge in diesel engines Be sure to consult an authorized service center when necessary Coast Distribution will maintain a service manual and parts breakdown on its website to guide the technician Go to www coastdistribution com for more information SAFETY INFORMATION WARNING Failure to properly follow these precautions can result in property damage serious injury or DEATH m Read all labels and the owner s manual before operating this generator m Operate only in ventilated areas gas contains carbon monoxide a poisonous colorless odorless gas and can be deadly Always stop the engine before refueling Wait 5 minutes before restarting Check for spilled fuel or leaks Clean and or repair before use Keep any source of combustion away from fuel tank at all times m Do not operate near flammable materials or in an explosive atmosphere Do not operate this unit in wet conditions or with wet hands Use of a generator in rain snow or near water can result in electrocution Keep the generator dry at all times Connections for standby power to a building s electrical system must be made by a qualified electrician and must comply with all applicable laws and electrical codes Improper connections can allow electrical current from the generator to back feed into the utility lines Such back feed may electrocute utility company workers or others who contact the lines during a power
19. paration for Starting euere een 7 4 Starting the Geleralgr uoi antt decade da kk n ke 11 5 Operating the Generator DARE AERE MEME 13 6 Stopping the Generalot an 15 Z P riodic Maintenance RR 16 8 Short term storage and maintenance 18 9 Long term SIOFAQO be Rn 19 10 Troubleshooting and 20 11 Wiring DIagEaltfis ci at ota tee e tl n bd dd qudd 22 12 EG EE PT 24 1 MAIN TECHNICAL SPECIFICATIONS AND DATA KDE5000E KDESOOOTA Jes Bune1ouay Rated frequency 2 60 60 Max power kVA 5 0 5 0 Rated power kVA 4 5 4 5 Rated voltage AC 120 240 120 240 Rated current AC 37 5 18 8 37 5 18 8 Rated speed rpm 3600 3600 Phase single phase Power factor 1 0 Excitation mode self excitation constant voltage AVR Structure mode Open Frame Sound Attenuating Enclosure Gross weight Ibs kg 201 95 376 171 Dimensions LxWxH mm 28 4x18 9x33 3 720x480x845 35 8x20 5x29 1 910x520x740 KDE5000E KDESOOOTA Model KM186FAG Type 4 stroke single cylinder air cooled direct injection diesel engine Continuous output kW rpm 6 3 6 3 Max Power kW rpm 6 6 6 6 Bore x stroke in mm 3
20. t operation 5 4 Electrical appliances particularly motor driven equipment will product very high current while starting The following table provides a reference for connecting these appliances to the generator EL STARTING RATED Incande scent lamp Heating applian ce Fluoresc ent lamp Motor driven equip ment EXAMPLE TYPICAL APPLIANCE APPLIANCE STARTING RATED ee lene 90680 100VA TV 100W w w 80VA 60VA W W Fluorescent Fluorescent lamp 450 750VA 300VA W Refrigerator 150W 6 STOPPING THE GENERATOR 1 Disconnect all loads 2 Turn off all circuit breakers Run the generating set without load for minutes 7 Do not stop the engine suddenly or the temperature will increase abnormally ij m Press down on the stop lever ee X m Turn the key to OFF m Place the fuel cock lever to S position top lever WARNING m f the engine keeps on running after the speed lever is placed in the STOP position turn the fuel cock to the CLOSE position m Do not stop the engine with the decompression lever m Do not stop the generating set with load applied Stop it after the load removed 7 PERIODIC MAINTENANCE Periodic maintenance is very important to keep the generator in optimum running condition The chart below indicates what checks and adjustments are necessary and at what interval Interval
21. the filler cap is securely closed after refueling m Be careful not to spill fuel when refueling If any fuel is spilled make sure the area is dry before starting the engine 3 2 Check and refill the engine oil WARNING m Always check the engine oil level with the generator on a level surface before starting and refill if necessary m The engine may be damaged if operated with insufficient engine oil it is also dangerous to overfill the oil level CAUTION KIPOR KDE series generators are equipped with a low oil pressure warning and shutdown system This system stops the engine automatically when the oil pressure falls below a safe level and prevents catastrophic engine failure Do not operate the generator with this system disabled m Check the oil level Take out the oil filler cap and clean the indicator stick with a clean lint free rag Reinsert the oil filler cap without rotating it Remove the oil filler cap and examine the oil level If the oil level is at or below the lower level refill the oil to the upper limit mark Reinsert the oil filler cap and tighten securely The oil capacity of the engine is 1 45 qt 1 65 L m Engine Oil Selection It is very important to select the proper engine oil to maintain good performance and life of the generator If an inferior engine oil or oil of the wrong grade is used or if your engine oil is not replaced periodically the risk of piston seizure piston ring st
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