IG6000 IG6000h - American RV Company
Contents
1. 7 5 Spark arrester maintenance A WARNING m f the generator has been running the muffler will be very hot Allow it to cool before proceeding A CAUTION m The spark arrester must be serviced every 100 hours to maintain its efficiency 1 Remove the two bolts securing the handle 2 Remove the rear cover bolts and carefully remove the rear cover 3 Unscrew the clamp on the spark arrestor and remove it from the exhaust pipe 4 Use a brush to remove carbon deposits from the spark arrester screen m Inspect the spark arrester screen for holes or tears Replace if necessary 5 Reinstall the spark arrester and tighten securely 23 6 Reinstall the rear cover Secondary air injection valve Rear cover Spark arrester 24 8 TRANSPORTING STORAGE 8 1 Transporting When transporting the generator turn the fuel valve lever OFF and keep the generator level to prevent fuel spillage Fuel vapor or spilled fuel may ignite Do not transport the generator in a vehicle with fuel in the tank 8 2 Exercising the generator It is essential that the generator be exercised on a regular basis This will prevent the accumulation of varnish or sludge in the fuel system and also remove moisture from the generator windings Additionally seals and other moving engine parts are kept lubricated and the battery is recharged Exercise the generator by running it with at least a 1 2 load 12. produce lower power and higher fuel consumption Do not use gasoline containing methanol 3 3 Air Cleaner Check the air cleaner elements to be sure they are clean and in good condition Open the service cover Remove the air cleaner cover and remove the paper air cleaner element Replace the element if dirty or damaged Air cleaner element Air cleaner cover Air Cleaner Assembly A CAUTION mM Never run the engine without the air cleaner Rapid engine wear will result from contaminants such as dust and dirt being drawn through the carburetor into the engine 4 SIARTING THE GENERATOR A CAUTION MWhen starting the generator after adding fuel for the first time after long term storage or after running out of fuel turn the fuel valve lever to the ON posit ion and then wait for 10 to 20 seconds before starting the engine 4 1 Starting Procedure A Turn the fuel valve lever to the ON position Fuel switch Fuel switch B Pull the choke knob out to the CLOSED position Do not use the choke when the engine is warm or the air temperature is high Choke knob Closed Choke C Insert the engine key and turn the engine switch to on position OFF Engine switch On Position D Turn the engine switch to the START until the engine has started Do not engage the starter for more than 10 seconds OFF Engine switch Starting Position E Push the choke knob to the OPEN
3. air cleaner cover 5 Close and latch the service door Air cleaner base Air Cleaner element Air cleaner cover 7 4 Spark plug service To ensure proper engine operation the spark plug must be properly gapped and free of deposits 1 Open the left side maintenance cover 2 Remove the spark plug cap Spark plug wrench Spark plug lever 3 Clean any dirt from around the spark plug base 4 Use the wrench to remove the spark plug 5 Visually inspect the spark plug Discard it if the porcelain insulator is cracked or chipped Clean the spark plug with a wire brush if it is to be reused 6 Measure the plug gap with a feeler gauge The gap should be 0 028 0 031 in 0 7 0 8 mm Correct 22 as necessary by carefully bending the side electrode Plug gap 0 7 0 8 i Fig 17 Spark Plug Gap A CAUTION mThe spark plug must be securely tightened An improperly tightened plug can become very hot and possibly damage the generator mNever use a spark plug with an improper heat range 7 Install the spark plug carefully by hand to avoid cross threading 8 After a new spark plug has been seated by hand it should be tightened 1 2 turn with a wrench to compress its washer If a used plug is being reinstalled it should only require 1 8 to 1 4 turn after being seated 9 Reinstall the spark plug inspection cover and tighten the cover screw 10 Close and latch the left side maintenance cover
4. conditioner manufacturers offer a start capacitor as an extra cost option The lack of a start capacitor can cause the air conditioner to draw too high a starting current and overload the generator Contact your air conditioner dealer if you consistently have problems starting your air conditioner with the generator This generator is not recommended for air conditioners exceeding 13 500 BTUs 14 5 7 DC application The DC receptacle may be used for charging 12 volt automotive type batteries only It is not designed to operate DC motors Output voltage is 15 30V DC output will vary according to the position of the Smart throttle switch 1 Connect the charging cable to the DC receptacle of the generator and then to the battery terminals Use only the charging cable supplied with the generator A WARNING H To prevent the possibility of creating sparks near the battery connect the charging cable first to the generator then to the battery Disconnect the cable first at the battery IM Before connecting the charging cable to a battery that is installed in a vehicle disconnect the vehicle s battery ground cable Reconnect the vehicle s ground cable after the charging cables are removed This procedure will prevent the possibility of a short circuit and sparks if accidental contact is made between a battery terminal and the vehicle s frame or body A CAUTION E Do not attempt to start an automobile engine with the generator still connected
5. mae Geese eo AA Es 20 7 3 Changing Oil ised SOLE Cee te Dad aes ees EOE Da Rtas tN ee Oe Cen esc Ot in caiac esc oct cae ee secondo 21 7 4 Air Cleaner Service PCC TCE eT ce Te a eer ee eee Ree an eee eee eae ee rere ny 21 7 5 Spark Plug Service sg sae eh taro EERTE a RI KA EE KON a dte EINE EE bce ech EE EE EE CD ERC EES a aa se 22 7 6 Spark Arrestor Maintenance EE Gnd ta Eny AY Da dan RR ATA IRA EERROR VERRE pieces BE RD anal RV av EES Ta a RU ESE RRR 23 8 TRANSPORTING STORAGE Dan a de deesses den a a ade San EAE a a Sa aa E E sa esata BA 25 8 1 Transporting RES OE ede sac Wy So EE El at WC nsdn Fibs W in Cage La a n a Si a Jn aCe n K deia Be Da are dE DE El dua a la we ka 25 8 2 Generator Exercise a D TTE Sa Evita AWA Mica min exw a TWAL TUR RRR RA ine SE NS ED BNE Le elo TAYE R 25 8 3 Extended Storage de Se oc ES MN RTO eee DE eae Se as ea ui a si ee ace ae a 25 9 TROUBLESHOOTING m n oa E l mo Te Ie aes AAA a acre n n a n R a a a a kn 26 9 1 No Start AT E TISE E m Tere re ee m E E Yn YA E ee geo re ice A S a Dill add E lon 26 9 2 No AC Power n PAAA n R AN SCARCE LULR CSE CA CCR EM in A ANEA E n n pm a eae Haa ea Toe 27 9 3 No DC Povver FITUR TT TK TB SO DD b k n ar arena SI Ed a DE A cbse wie BE a Da El e APA wae ere A TT 27 10 SPECIFICATIONS m at dni Cer Tr ee Roe oe eee Tee eT eT eee eT ee eee ia din eee E A db 28 11 WIRING DIAGRAM S enamine Sh tne BN GARD PEAR EREE RR VERRP YAAA Bao aan SITES EI EE OCI 29 12 WHEEL KIT INST
6. position as the engine warms up Na The choke is open 4 2High altitude operation At high altitude the standard carburetor air fuel mixture will be excessively rich Performance will decrease and fuel consumption will increase High altitude performance can be improved by installing a smaller diameter main jet in the carburetor If you continuously operate the generator at altitudes higher than 5000 feet or 1500 meters above sea level have your authorized dealer install the high altitude main jet kit No other adjustments to the carburetor are necessary Even with suitable carburetor re jetting engine horsepower will decrease approximately 3 5 for each 1000 feet or 305 meter increase in altitude The effect of altitude on the horsepower will be greater than this if no carburetor modification is made For use at lower altitudes be sure to have your dealer return your generator to the original specification A CAUTION E Operation of the generator at an altitude lower than the carburetor is jetted for may result in reduced performance overheating and serious engine damage caused by an excessively lean air fuel mixture 4 3 Ambient Temperature Generator output generally derates 1 for every 10 F 5 5 C above 85 F 29 C The normal operating range of the generator is 20 to 113 F 29 to 45 C A CAUTION E Do not operate the generator when the ambient temperature is below 20 F 29 E Do not ope
7. spark Spilled fuel may ignite plug in the plug cap 3 Set the plug side electrode on the cylinder head to ground 4 Crank the engine sparks should jump across the gap Is the fuel reaching the Clean the fuel filter cap carburetor To check 1 Turn off the fuel valve and loosen the drain screw If the engine still does not start take the generator to an authorized KIPOR dealer 2 Fuel should flow from the drain when the fuel valve is turned on 26 9 2 No AC Povver Appliance does not operate Is the output indicator light ON Is the overload Take the generator to an indicator light ON authorized dealer Check the electrical appliance or Take the generator to an equipment for any defects authorized KIPOR dealer H Replace the electrical appliance or equipment H Take the electrical appli ance or equipment to an electrical shop for repair 9 3 No electricity at the DC receptacle YES Is DC circuit fuse burned out Replace the fuse Take the generator to an authorized KIPOR dealer 27 10 SPECIFICATIONS Generator Model IG6000 IG6000h Rated frequency Hz 60 Rated voltage V 120 240 Rated current A 45 8 22 9 Rated output Watts 5500 Max current A 50 Max output Watts 6000 DC voltage 12V 5 0A Phase Single Engine Model KG390GTi Type Single cylinder 4 stroke vertical air cooled OHV gasoline engine Displace
8. to battery The generator may be damaged MConnect the positive battery terminal to the positive charging cord Do not reverse the charging cables or serious damage to the generator and or battery may occur d WARNING M The battery gives off explosive gases keep sparks flames and cigarettes away Provide adequate ventilation when charging M The battery contains sulfuric acid electrolyte Contact with skin or eyes may cause severe burns Wear protective clothing and a face shield A If electrolyte gets on your skin flush with water B If electrolytes gets in your eyes flush with water for at least 15 minutes and call a physician H Electrolyte is poisonous If swallowed drink large quantities of water or milk and follow with milk of magnesia or vegetable oil and call a physician 15 H Keep out of reach of children 1 CAUTION The DC output is to be used to charge batteries only Serious damage to the stator windings can occur if connected to a DC motor or transformer 2 Start the generator H The DC receptacle may be used while the AC power is in use H The DC receptacle is protected from an overload with a fuse If the DC circuit is overloaded the 5 amp fuse will blow and power to the DC receptacle will cease The red light on the DC panel will illuminate The fuse is located in the receptacle and is accessed by snapping open the fuse panel Replace the fuse with one of the same capacity Using a higher rated f
9. 500W for 60 minutes per month Gasoline fuel treatments to prevent contamination of your fuel supply are available from your dealer Fuel varnishing necessitating replacement of the carburetor is not a warrantable failure 8 3 Extended storage 1 Ensure the storage area is free of excessive humidity and dust 2 Drain the fuel A Open the left side maintenance cover B Turn fuel valve lever to ON and then loosen the carburetor drain screw Drain the gasoline from the carburetor and fuel tank into a suitable container Drain plug 3 Once a month recharge the battery 4 Change the engine oil 5 Remove the spark plug and pour one tablespoon of clean engine oil into the cylinder Crank the engine several revolutions to distribute the oil and then reinstall the spark plug 25 9 TROUBLESHOOTING 9 1 No Start NO Is there fuel in the tank Refill the fuel tant I YES NO Is the engine switch on PI Turn the engine switch on YES NO Is the fuel valve on Turn the fuel valve on NO YES Is the enough oil in the engine gt Add the recommended oil YES NO Still no spark Take the generator to Is there a spark from Replace the an authorized KIPOR the spark plug spark plug dealer WARNING To check 1 Remove the spark plug cap and clean any H Be sure there is no spilled dirt from around the spark plug fuel around the spark plug 2 Remove the spark plug and install the
10. ALLATION ada aa Ed a da E E m Bye n YE m a R R aa ae arena e ka e SY KAR 30 12 1 IG6000 So En dte se ia deia Sa io a ee eR ee EC EB eRe ED ED ES A N k Re oR oe W rere eee ie En 30 12 2 IG6000h Bese Aimee wie DD Ba Da iaia ta EE ADE in whew ar BOE EE Ed RETR my Haia ia Gena dia aa nies dia a dra are IE a DL llati a Geese din ad Rialles 31 13 VVARRANTY dela Pm n deia ai E Bac masa eee ere ee Pe eee eT eer ee a cin nia Reece ep eee ee a eee si amic eo 32 13 1 Limited Warranty Kipor Power Products RI EEVEE a Tatar EE CE ENEE DE OE EE P 32 13 2 Emission Control VVarranty a WEE RE AEREE EOAR ENRE RRR OER RE ERA GEREEN ERRE RERE E RR VERR 33 14 EMISSION CONTROL SYSTEM ada aa E L ada CL lada EE E A T ae ae S esa ciar ate 34 1 SAFETY INSTRUCTIONS MThe generators are designed to give safe and dependable service if operated according to the instructions Read and understand the Owner s Manual before operating the generator Failure to do so could result in personal injury or equipment damage A WARNING MExhaust gas contains poisonous carbon monoxide a colorless odorless poisonous gas Never fun the generator in an enclosed area Be sure to provide adequate ventilation A WARNING H The muffler becomes very hot during operation and remains after the engine has stopped Be careful not to touch the muffler while it is hot Let the engine cool before storing the generator indoors A WARNING E Gasoline is extremely fla
11. ATION 12 1 IG6000 1 VVasher 4 2 Front Wheel 2 3 Wheel Clip 2 4 Locking Swivel Wheel 2 5 Bolt M6X16 8 To install the front wheels install a washer on the axle then the wheel another washer and secure with a wheel clip To install the locking swivel wheels line up the bolt holes in the chassis with the holes in the wheel attaching plate Secure with the 4 bolts 30 IG6000H 1 IG6000H Chassis installed 5 10 Wheel 2 Support Bracket 4 6 Wheel Washer 4 3 Front Stabilizer 2 7 Wheel Clip 4 Axle Assembly Assembly 1 Install the four support brackets and secure with bolts 2 Attach the front stabilizers to the chassis below the handles 3 Attach the axle assembly 4 Install one washer on the axle against each welded stop 5 Install the two wheels 6 Install the two remaining washers and secure with the wheel clips The handles are preassembled before packaging To raise the handles simply raise the handle assembly to a horizontal position To retract the handles slide the chrome collars toward you to clear the sleeve and lower them to the starting position 31 13 WARRANTY 13 1 Limited Warranty Kipor Power Equipment LENGTH OF WARRANTY Generators are covered by this warranty from the date of original retail purchase for a period of two years for residential use and one year for commercial applications Units used in rental fleets or as demonstration models will be con
12. KIPOR KIPOR WUXI KIPOR POWER CO LTD WUXI KIPOR POWER CO LTD Beside Jingyi Road Third Stage Development Section of Wangzhuang Industry Area Wuxi High amp New Technology Industry Development Zone Wuxi Jiangsu Province PRC TEL 0086 510 85200888 FAX 0086 510 85200999 E MAIL kipor kipor com SINEMASTER DIGITAL GENERATOR IG6000 IG6000h OWNER S MANUAL Version 2 Printing date December 29 2008 Coast CARB MADE IN CHINA PREFACE Thanh you for purchasing a RIPOR generator from the Coast Distribution System This manual covers operation and maintenance of the California Air Resources Board CARB approved IG6000 and IG6000h generator All information in this publication is based on the latest product information available at the time of approval for printing We reserve the right to make changes at any time without notice and without incurring any obligation No part of this publication may be reproduced without written permission This manual should be considered a permanent part of the generator and should remain with it if it is resold Pay special attention to statements preceded by the following words Failure to properly follow these precautions can result in property damage A WARNING serious injury or DEATH Read all labels and the owner s manual before operating this generator Generators produce carbon monoxide a poisonous colorless odorless gas that can cause death or serious inj
13. als dr nata Ie da nen ib mre AEEA Bien Bien eh Br RCO elie TR intone Que ESE EE fa A 11 5 2 AC Povver Applications Mise ee Oa hoe t SEE caca aci Gai ca iode dan EAT Ot imeem eee kanes 12 5 3 Output and Overload Indicators ETC CCC eee CCRC Te ee ee eee coe eee a n E AE eee eer 12 5 4 AC Load Management l T ai f k RA AW Re WOU ST inte ive RAVE KAYE a JET ET RES On DR Gnd AA Mujer AP Ell AT ESC pure BOLA a le EO euler ET 13 5 5 Smart Throttle i ah eae ce Shit Sire RR wife eta Wie OD ec wh BG Ohi eile o DE OE i ena et 14 5 6 Air Conditioning Operation De ed na see a Be n eis E cadena n m mens PS E ia va ee 14 5 7 DC Povver Operation Dia EO Ed aa ae ao Edad a ad en ie cas io patata ie NOR da CS apa aa PEC Mo Jace ta n l k wie ia we ki 15 5 8 Low Oil Alarm System je ine ALA eee diaria sein ZO LA wie aw corel dia a ia DA w e 6B Bi n Siem m DL oie dE BAD MA T 16 6 STOPPING THE ENGINE m Sm EE yn m ncia E mca ieee ad dia ates A KAI domini a da m n aioe am dama datat 17 6 1 Normal Shutdown Vekk EC EE ESE EE TRAC EE EE DR ES EE eT CT eo EE rar 17 6 2 Emergency Stop BAY at jue B L or char ara ater RRR DERRE e On GP ZO a YO acm Ga SPAKENE RER VERRE FAR BED ao ant ate aig 17 7 MAINTENANCE a ee e aa mada a m e e ae a n n ea a mida E Yi E N a mn 18 7 1 Emission Control System VEKK TON ROL EEES BO CE W ara ERE ERR KOR Bi KON EE eee KA 18 7 2 Maintenance Schedule DS mio RAB m ian Sals Gr BOE MI Sib dE ay Wie a Kare Geeta wt RURA RRR RTA RV Bp
14. and keep this manual in a safe place along with the bill of sale Serial Number Bar Code Number Date of Purchase 365625d 3 PRE OPERATION CHECR Be sure to check the generator on a level surface with the engine stopped 3 1 Engine Oil A WARNING H Using non detergent or 2 stroke engine oil could shorten the engine s service life H Use a high detergent premium quality four cycle engine oil certified to meet or exceed U S Automobile manufacturer s requirements for API Service Classification SG SF H Select the appropriate viscosity for the average temperature in your area SAE Viscosity Grades M l i 100 F Ambient Temperature Open the service door Remove the oil filler cap and wipe the dipstick with a clean rag Engine oil capacity is 1 2 quarts or 1 1 liters Check the oil level by inserting the dipstick in the filler hole without screwing it in If the oil level is below the end of the dipstick refill with recommended oil up to the top of the oil filler neck Upper limit Lower limit 4 CAUTION IM Running the engine with insufficient oil can cause serious engine damage H The oil Alert System will automatically stop the engine before the oil level falls below the safe limit However to avoid the inconvenience of an unexpected shutdown it is still advisable to visually inspect the oil level before each use 3 2 Fuel Use unleaded 87 octa
15. ay affect emission Any of the following faults must be repaired immediately Consult with your authorized Kipor service center for diagnosis and repair Hard starting or shut down after starting Unstable idle speed Shut down or backfire after applying an electrical load Backfire or afterfire Black smoke and or excessive fuel consumption 18 Replacement parts and accessories The parts making up the emission control system applied to Kipor engine have been specifically approved and certified by the regulatory agencies You can trust the replacement parts supplied by Kipor have been manufactured to the same production standard as the original parts The use of replacement parts or accessories which are not designed by Kipor may affect the engine emission performance The manufacturers of replacement parts and accessories have the responsibility to guarantee that their replacement products will not adversely affect emission performance Maintenance Maintain the generator according to the maintenance schedule in this section Service items more frequently when used in dusty areas or under conditions of high load temperature and humidity Air Quality Index California certified models CARB requires that an air quality index label be attached to every certified engine showing the engine emission information for the emission duration period The label is provided for the user to compare the emission performance of different engines The lo
16. d indicator light red and the output indicator light green lights may go on simultaneously This is normal if the overload indicator light red goes off after about four 4 seconds If the overload indicator light red stays on consult you dealer 13 5 5 Smart Throttle Engine speed is kept at idle automatically when the electrical load is disconnected and it returns to the proper speed when the load is reconnected This position is recommended to minimize fuel consumption while in operation Smart throttle Smart Throttle Switch A NOTE H When high electrical load appliances are connected simultaneously turn the smart throttle switch to the OFF position to reduce voltage changes H Smart throttle system does not operate sufficiently if the electrical appliance requires the much electric power 5 6 Air Conditioning Operation For best results the SMART throttle switch should be in the off position Bring the generator to a normal operating temperature before applying the air conditioning load Always allow a 2 minute wait period when manually cycling an air conditioner off and on A longer wait period may be required under unusually hot weather conditions Additionally all other loads should be turned off until the air conditioner has started and is performing normally It is also important to follow the air conditioner manufacturer s instructions for starting and restarting for proper operation Some air
17. e Manual Part Description Coast Distribution Number Spark Plug 66164 Air Filter Element 66191 Fuel Strainer 66262 Spark Arrestor 66242 To locate a parts dealer in North America visit the website www kipornorthamerica com 20 7 3 Changing oil Drain the oil while the engine is still warm to assure rapid and complete draining See Fig 15 Lower limit a Oil drain bolt Dipstick 1 Open the service door 2 Take out the oil outlet plug 3 Remove the drain bolt and drain the oil Retighten the bolt securely 4 Refill with the recommended oil and check the level 5 Close the service door Engine oil capacity 1 29t 1 1 liter 7 3 Air cleaner service A dirty air cleaner will restrict air flow to the carburetor and allow dirt to enter the combustion chamber Service the air cleaner regularly Service more frequently when operating the generator in extremely dusty areas A WARNING mDo not use gasoline or low flash point solvents for cleaning they are flammable and explosive under certain conditions A CAUTION mNever run the generator without the air cleaner Rapid engine wear may result 21 1 Open the left side maintenance door 2 Unsnap the clips and remove the air cleaner cover 3 Remove the air cleaner element and examine for dirt or damage Replace it vvith a nevv one if necessary Do not attempt to clean the paper element 4 Reinstall the
18. ed by the warranty administration center In the event that the generator is deemed not repairable or the necessary repair would be economically unfeasible Coast will pay for shipping of the unit from the repair center to the designated Coast facility and the shipping of a replacement unit 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 Engine serial number bar code number and proof of purchase are required EXCLUSIONS This warranty does not extend to parts affected or damaged by accident and or collision normal wear fuel contamination or degradation use in an application for which the product was not designed or any other misuse neglect incorporation or use of unsuitable attachments or parts unauthorized alteration or any causes other than defects in material or workmanship This warranty does not extend to normal maintenance items such as belts hoses spark plugs and filters past the first scheduled replacement or s
19. ervice interval for these items whichever comes first Coast will pay for minor adjustments for a period of ninety days from the purchase date of the generator 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 loss or any other incidental or consequential damage Any implied warranties are limited to the duration of this written limited 32 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 13 2 Emission Control System Warranty Your Kipor generator engine complies with U S Environmental Protection Agency Environment of Canada and the state of California The following systems and or parts are covered by this warranty Failures or improper operation of the following systems and components will be diagnosed and repaired with no charge for labor or parts Fuel System e Carburetor including the choke system and replaceable high altitude main jets e Engine speed control system Smart Throttle e Intake manifold e Engine control module Engine control function only Evaporative Control System e Fuel tan
20. ge Cords a 14 gauge cord between 0 and 50 feet long will adequately handle loads between 10 and 15 amps 12 Gauge Cords If your load is between 10 and 15 amps and the length of the cord is 50 to 100 feet you need a 12 gauge cord to safely power any tool HKeep the generator away from other electric cables or wires such as commercial power supply lines Grounding the Generator 11 5 2 AC applications 1 Start the engine and make sure the output indicator light green comes on 2 Confirm that the appliance to be used is switched off and plug in the appliance Applying Loads A CAUTION MSubstantial overloading that continuously lights the overload indicator light red may damage the generator Marginal overloading that temporarily lights the overload indicator light red may shorten the service life of the generator HBe sure that all appliances are in good working order before connecting them to the generator If an appliance begins to operate abnormally becomes sluggish or stops suddenly turn off the generator engine switch immediately Then disconnect the appliance and examine it for signs of malfunction 5 3 Output and Overload Indicators The green output indicator light will remain on during normal operating conditions If the generator is overloaded to the point that the max power t 5 rating of 25 amps is exceeded or if there is a short in the connected t 2 appliance the output indicato
21. is well ventilated The exhaust contains poisonous carbon monoxide gas 7 1 Emission Control System Emission source Exhaust gas contains carbon monoxide nitrous oxide NOx and hydrocarbons It is very important to control the emissions of NOx and hydrocarbons as they are a major contributor to air pollution Carbon monoxide is a poisonous gas The emission of fuel vapors is a source of pollution as well The Kipor generator engine utilizes a precise air fuel ratio and emission control system to reduce the emissions of carbon monoxide NOx hydrocarbons and evaporative fuel emissions Regulation Your engine has been designed to meet current Environmental Protection Agency EPA and the California Air Resources Board CARB clean air standards The regulations dictate that the manufacturer provide operation and maintenance standards regarding the emission control system Tune up specifications are provided in the Specifications section and a description of the emission control system may be found in the appendix to this manual Adherence to the following instructions will ensure your engine meets the emission control standards Modification Modification of the emission control system may lead to increased emissions Modification is defined as the following e Disassembling or modifying the function or parts of the intake fuel or exhaust system e Modifying or destroying the speed governing function of the generator Engine faults that m
22. k e Fuel cap e Fuel strainer e Fuel valve e Fuel lines e Carbon canister including brackets and connectors Air Induction System e Air filter element e Air filter housing Ignition system e Ignition module e Ignition coil e Ignition winding e Ignition trigger e Spark plug e Spark plug cap and wire Exhaust system e Catalyst e Exhaust manifold e Secondary air injection assembly Miscellaneous e Pipes tubes hoses and clamps o rings seals and gaskets associated with the above systems Covered up to the first scheduled replacement only See the maintenance schedule 33 14 EMISSION CONTROL SYSTEM Your generator has an engine that has been approved by the California Air Resources Board Other than the tune up procedures specified in the maintenance section no additional maintenance is required The emission control system has the follovving components 1 Fuel System The fuel tant cap indicator and hoses are specially designed and constructed to not allovv fuel vapors to permeate and be released to the atmosphere 2 Acarbon activated canister collects gasoline vapors from the fuel tank and returns them to the combustion chamber for burning 3 Acatalyst is built into the muffler to further treat the engine exhaust A secondary air injection valve adds combustion air to ignite unburned fuel in the exhaust Contact your authorized Kipor service center to obtain the correct replacement parts a
23. ment Bore x Stroke 23 7 cu In 389 cc Compression ration 8 5 1 Rated power kW hp r min 7 7 3600 Rated rotation speed rpm 3600 Ignition system T C I Spark plug WR7DC Starting system Electric starter Fuel Automotive unleaded gasoline 87 octane Lube oil SAE 10W30 see viscosity chart Lube oil capacity 1 2 qt 1 1L Fuel tank capacity L 5 3gal 20L Continuous running time at rated 6 8 Hours output Noise level zero load full load 23 7M 64 65 decibels Tune Up Specifications Spark Plug Gap Valve Clearance cold Intake Valve Clearance cold Exhaust 0 024 0 028 in 0 6 0 7 mm 0 0039 0008 in 0 10 0 02 mm 0 0059 0008 in 0 15 0 02 mm Dimensions Overall dimension LxWxH in mm IG6000 31 6x19 5x24 6 802x495x624 IGGOOOh 48 6x25 59x30 3 1235x650x770 Dry weight lbs kg IG6000 95 209 IG6000h 115 263 28 11 WIRING DIAGRAM Blue FH Blue edi ds IB DC Winding Blue mm eo Rectifier bridge Black yo Blak n Main winding Black a l D 5 8 White Red g F Vice winding White L5 30 14 50 RU 22 Red Main winding Red ak F Green f Vice winding Green Yellow me S Grey 7 3 relay Stool ka Red A ESE m E VS 3 2 2 White 613 5 65 LJ Black 5 e Oil ine magnet valve 29 12 VVHEEL INSTALL
24. mmable and explosive under certain conditions Refuel in a well ventilated area with the engine stopped Keep away from smoking materials sparks and other sources of combustion when refueling the generator mM Wipe up spilled gasoline immediately A WARNING H Connections for standby power to a building 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 outage and when utility power is restored the generator may explode burn or cause fires in the building electrical system A WARNING Always make a pre operation inspection before you start the engine H Place the generator at least three feet or one meter away from buildings or other equipment during operation E Operate the generator on a level surface to prevent fuel spillage and oil starvation E Know how to stop the generator quickly and understand the operation of all the controls Never permit anyone to operate the generator without proper instruction HKeep children and pets away from the generator when it is in operating HKeep away from rotating parts while the generator is running H The generator is a potential source of electrical shocks when misused do not operate with wet ha
25. nd service on this system Intake System Air filter shell Fixed bracket Sealing gasket Air filter cover s Filter element s N ES hi A N Carburetor 34 Exhaust system Secondary air injection valve Muffler assembly Muffler gasket Exhaust pipe 35 Carbon Canister Installation Strap Curved hose Canister 36 Fuel System Fuel tank cover wa LA q SN Sleeve Bushing Pin VVasher Strainer C Gasket Hook i _ Certificate No X6800BM Q 08 006 Gas tank Certificate No C U 07 016 Mounting strap Fuel switch Carbon Canister Fuel hose il Screw w Certificate No C U 05 012 Curved hose Vent hose Bracket Bolt Air filter connection 37
26. nds Do not operate the generator in rain or snow or allow it to get wet 2 COMPONENT LOCATIONS 2 1 Outside vievv Spark plug Service door Control panel Air intake Oil drain screw Dipstick Air filter Fuel level indicator Fuel filler cap lt Air quality index Air exhaust Muffler warning 2 2 Control panel Choke knob DC Receptacle Smart switch Start switch Ground terminal Fuel switch Annunciator Panel 2 3 Serial Number and Bar Code Location The engine serial number is stamped on the engine block to the left of the oil drain plug In most cases the battery will have to be removed to view it clearly Refer to this number when ordering parts or making technical inquiries 08031 2356800300G P0342 Y L I SN Product DIGITAL INVERTER GENERATOR g Spec 1G3000 SON LEZ N Date 2008 02 12 Ik No VW J S ag J SA la sy NN gt 1 L fe Ws RC Ke yo i NA R Ne Engine serial number The bar code label is found in three locations on the generator chassis belovv the service door on the packing carton and on the owner s manual inside cover The bar code identifies the production date and is used by your dealer and the customer service center for warranty administration Please record this information below
27. ne regular gasoline Do not use premium or high octane fuels The engine is tuned to run on regular gasoline and engine damage and poor performance may result from using higher octane fuels If the fuel level is low refill to the shoulder of the fuel strainer Never use an oil gasoline mixture or dirty gasoline Avoid getting dirt dust or water in the fuel tank After refueling tighten the fuel filler cap securely A WARNING E Gasoline is extremely flammable and is explosive under certain conditions HRefuel in a well ventilated area with the engine stopped Do not smoke or allow flame or sparks in the area where the engine is refueled or where gasoline is stored M Do not overfill the fuel tank there should be no fuel in the filler neck After refueling make sure the fuel filler cap is closed properly and securely HBe careful not to spill fuel when refueling Spilled fuel or fuel vapor may ignite If any fuel is spilled make sure the area is dry before starting the engine MAvoid repeated or prolonged contact with skin or breathing of vapors KEEP OUT OF REACH OF CHILDREN Fuel tank capacity 5 3 gallons or 20 liters Fuel surface 1 Strainer Fuel level 6 GASOLINES CONTAINING ALTERNATE FUELS If you decide to use a gasoline containing ethanol or methanol be sure its octane rating is no lovver than the specification Do not use a blend that contains more than 15 ethanol An ethanol blend will
28. r 1 2 COMPONENT LOCATIONS fag oh Bien dida a dra ESE IE chy Be Bale my darrer cie EE Deia BY ABA IE mes Gaya kf vev Be ayy vr Ed 3 2 1 Outside View Hatt SOU Sue eet ee A aca i ac SOC Oud coc ai tac ca coet cai EEES tenons 3 2 2 Control Panel Bisa tasca arith Ei oe aa pensa a diaca n pia Ec ates aca se atacar a dama E cdc whadu m n dites mi arm oleae 4 2 3 Serial Number and Bar Code Location a EE Lc a a TL CER ei r RR EB rk 4 3 PRE OPERATION CHECK Sila Es dei atm os aula ares R i ES weiner E o ea n a eee ete 5 3 1 Engine Oil KKR RR era eye wide mt ese m esas EC see a daca A EA ada e E e ne aa ara da Sa a Die anit id na ARR data 5 3 1 Fuel d ac sada ap Era dd a DES Bo pees Tay dE A d ai na ia nt a OE DUE JRC EES Jn oor m kn AD a ESE DE OS a DD aa as i tada NE oi m teca as 6 3 3 Air Cleaner Esta GGL MAR ay WA YA an Bie im A ROL IS YA A SI a e AGO f A K A bre DD TT TANTA TT m BO LA P a amp 7 4 STARTING THE ENGINE Baie llac ataca a m dE weasel m e E n n n n a a Es m m add n nid n a a e fan ra m T E 8 4 1 Starting Procedure da af seed ata da ase atlas n a a n n OE a Wo L MO EE SU A Bo EES ESE EC accor W 8 4 2 High Altitude Operation BONN a EE ala EE EEEE KO A By ead de EE aide wat wi imine ON BI ANA EO ERR EC EET a oa ds DO mn em and RR 10 4 3 Ambient Temperature MO CREO ICR CEE ES EE a as i OS di ES ere 10 5 GENERATOR USE Pe eae ea Ree eae OPTIC ea oC eR ie oe eee gor coe Da a Ree ie AN fr 11 5 1 Warnings and Cautions Ga Hie ms dia DE Ban S
29. r will go out and the overload indicator id OF will go on and current to the connected appliance will be shut off 1 8 K Low Ot Stop the engine if the overload indicator light comes ON and investigate the overload source The engine will continue to run even though it is not producing any AC power The engine must be stopped and then the generator restarted to resume normal operation The 20A duplex receptacle is protected by a push button style circuit protector If the current load exceeds 20 amps the button will pop and current is shut off to the receptacle Reduce the load and push the button back in to restore current 12 5 4 AC Load Management The generator has the follovving receptacles 1 240V 50A 14 50R 1 120V 20A 5 20R duplex 0 900 CEATIFICATION so 1 120V 30A L5 30R twistlock Maximum load from the various receptacles is as follows 240V AC at 25 amps is available from the 50A receptacle Connecting this receptacle to a 50A service receptacle will allow 25 amps Q 120 volts to two separate legs 25 amps from the L5 30R twist lock receptacle 25 amps from the duplex receptacle Simultaneous operation of 120 and 240 volt appliances is possible but the total amperage of the applied loads cannot exceed the generator receptacle rating Under no circumstances will the generator permit any AC load greater than 25 amps to any one receptacle H When an electric motor is started both the overloa
30. rate the generator when the ambient temperature is above 113 F 45 C 10 5 GENERATOR USE 5 1 Warnings and Cautions A WARNING H To prevent electrical shock from faulty appliances the generator should be grounded The ground terminal is connected to the generator frame and the ground terminal of each receptacle Connect a length of heavy gauge wire between the generator s ground terminal and an external ground source if required by local code A e H Limit operation requiring a maximum power rating of 6000 watts to 30 minutes For continuous operation do not exceed the rated power of 5500 watts In either case the total wattage of all appliances connected must be considered IM Do not exceed the current limit specified for any one receptacle IM Do not connect the generator to a household circuit This could cause the damage to the generator or to electrical appliances in the house MDo not modify or use the generator for other purposes than it is intended for Also observe the following when using the generator A Do not connect generators in parallel B Do not connect an extension to the exhaust pipe C Do not operate the generator with any covers removed or in a closed compartment MWnhen an extension cable is required make sure you use the proper size and length 16 Gauge Cords Any 16 gauge cord between O and 100 feet long will adequately handle tool and appliance loads up to 10 amps 14 Gau
31. sidered commercial usage Starting batteries included with a generator are warranted for a period or one year Kipor must warrant the emission control system for a period of two years provided there has been no improper maintenance abuse or neglect See the emission control warranty in the section immediately following the limited warranty description 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 the United States or Canada from an authorized Coast Distribution 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 Warranty coverage will only be provided by authorized Coast Distribution dealers in the United States and Canada COVERAGE Parts labor and regular shipping costs will be covered by Coast Distribution for any failure that is proven to be a failure of material or workmanship under normal use during the applicable warranty time period It is the responsibility of the end user to return the product to the nearest authorized repair center as direct
32. ury Indoor use of a generator can kill quickly Generators should be used outdoors only Do not operate this generator inside any enclosed compartment This includes an RV generator compartment Generators should be used outdoors only and away from garages and open windows and protected from rain and snow Check for spilled fuel or leaks Clean and or repair before use Always stop engine before refueling Wait 5 minutes before restarting Keep any source of ignition away from fuel tank at all times The portable generator is not meant to be used as a permanent back up power system for the home A permanently installed stationary generator is designed to be safely used for this specific purpose Indicates a strong possibility of severe personal injury or death if instructions are not followed Indicates a possibility of personal injury or equipment damage if instructions are not followed NOTE Gives helpful information If a problem should arise or if you have any questions about the generator consult an authorized KIPOR dealer KIPOR generator is designed to give safe and dependable service if CAUTION 3 ka a p operated according to instructions Read and understand the Owner s Manual before operating the generator Failure to do so could result in personal injury or equipment damage CONTENTS 1 SAFETY INSTRUCTIONS TKR RRR n aca aci aa ny Woe acc wa at doc aa Wine bm atic RR a Wok so ED ee bse cau wate Want Won et Sete
33. use may cause damage to the generator alternator Fuse DC receptacle 5 8 Low oil alarm system The low oil alarm system is designed to prevent engine damage caused by an insufficient amount of oil in the crankcase Before the oil level in the crankcase falls below a safe limit the low oil alarm system will automatically shut down the engine the engine switch will remain in the ON position If the low oil alarm system shuts down the engine the red low oil alarm indictor light will come on when you operate the starter and the engine will not run If this occurs search for any oil leaks Add engine oil to resume normal operation OFF 4 OUTPUT INDICATOR OVERLOAD lt ALARM LOW OIL 4 ALARM 16 6 STOPPING THE GENERATOR 6 1 Normal Shutdown In normal use 1 Switch off the connected equipment and pull the plug from the receptacle 2 Turn off the engine switch 3 Turn the fuel valve lever to the OFF position 6 2 Emergency Shutdown To stop the generator in an emergency turn the engine switch to the OFF position A CAUTION E Continually stopping the generator with a load applied can lead to eventual damage of the inverter module 17 7 MAINTENANCE The purpose of the maintenance and adjustment schedule is to keep the generator in the best operating condition E Shut off the engine before performing any maintenance If the engine must be run make sure the area
34. wer the air index the better the engine emission performance The description of durability is helpful for the user to learn the engine emission duration period and the service life of emission control system Refer to the warranty section of this owner s manual for more information Description Emission duration period Short term 50 hrs 0 80CC 125 hrs gt 80CC Medium term 125 hrs 0 80CC 250 hrs gt 80CC Long term 300 hrs 0 80CC 500 hrs gt 80CC 1000 hrs 2225CC H Use genuine Kipor parts or the equivalent The use of replacement A CAUTION parts which are not of equivalent quality may damage the generator 19 7 2Maintenance Schedule Peston vi Mbeki oF FIRST EVERY 3 EVERY 6 EVERY operating hour interval whichever PACH MONTER MONTHS MENTS MONTES occurs first USE OR OR OR OR ITEM 20HRS 50HRS 100HRS 300HRS Engine oil Check O Change O O Air cleaner Check O Clean O 2 Spark plug Clean adjust O Spark arrester Clean O Fuel sediment cup Clean O Valve clearance Clean adjust O 3 Fuel tank and strainer Clean O 3 Fuel line Check Every 2 years Replace if necessary 3 NOTE 1 Log hours of operation to determine proper maintenance 2 Service more frequently when used in dusty areas 3 These items should be serviced by an authorized dealer unless the owner has the proper tools and is mechanically proficient See the Servic
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