IG3000 - Kipor Generators, Reliance Controls
Contents
1. Replace the throttle control motor a Abnormal Check the smart switch Replace the smart switch a i Abnormal i j Check each Smart switch orma Repair or replace the wire connection harness y Replace the invert unit 14 H No or Low AC output ar ON i Is the overload indicator light ON Disconnect the load and restart the engine J orF Is the engine speed normal Ab i Engine speed nerna Perform the throttle control Smart switch ON 3000 100rpm system troubleshooting Smart switch OFF 3600 100rpm i Normal Engine stopped and check AC Abnormal _ gt receptacle Replace the AC receptacle i Normal Disconnect thr 6P connector from the invertrt unit Pull the recoil starter and measure the AC voltage between the white and Check and repair the harness black terminals Voltage Abnormal _ of stator or replace the stator A p gt 120V model Magnetic force of the rotor black black gt 30V magnet is low Replace the white white gt 1V rotot 230V 240V model black black gt 60V White white gt 1 Normal Replace the inverter unit The stator output may be checked with the engine running Disconnect the 6P connector from the inverter unit starting Check voltage between pins 1 amp 4 pins 2 amp 4 and pins 1 amp 2 There should be 280 to 330 Volts AC If one or more2. Forced air Ignition system T C l Ignition timing 25 B T D C Spark plug F7RTC Carburetor Float type horizontal butterfly valve Air cleaner Semi dry Governor Electronic control Lubrication system Forced splash Oil capacity 63 qt 0 6L Fuel tank capacity 3 43 gal 13L Starting system Recoil starter and Electrical starter Stopping system Primary circuit ground Fuel Unleaded gasoline 87 octane Alternator Model KD 35 Generator type Multi pole rotation type Generator structure Self ventilation drip proof type Excitation Self excitation Magnet type Voltage regulation system PWM Plush width modulation Phase Three phase Rotating direction Clockwise Viewed from the generator Frequency regulation 1 2 CHARACTERISTICS Model AC DC AC conversion Inverter type KGE3000Ti KGE3500Ti Maximum output watts amps 3000 25 Amps Rated output watts amps 2800 23 Amps Rated frequency 60 HZ Rated voltage AC 120V DC Voltage current 12V 8 3 Amps Power factor 1 0cos Voltage variation rate Momentary Average Average time 10 max 1 5 max 3 sec max Voltage stability 1 Frequency variation rate Momentary Average time 1 max 1 max 1 sec max Frequency stability 0 1 Insulation resistance
3. 10MQ min AC circuit protector 26A 120V DC circuit protector 14A Operating hours at rated load 7 Hours Noise level dBA 23 7M 62 67 1 3 PERFORMANCE CURVES The curves show performance of the generator under average conditions Performance may vary to some degree depending on ambient temperature and humidity The output voltage will be higher than usual when the generator is still cold immediately after the engine starts AC external characteristic curve oO F po 120 es gt mM 5 EL 2 110 O lt Current A 0 5 10 15 20 25 DC external characteristic curve 26 2 24 g 22 Q 20 3 18 5 16 Oo Moo o 14 oa Q 12 Current A 0 2 4 6 8 0 2 1 4 DIMENSIONAL DRAWING 1 5 WIRING DIAGRAM DC socket Charging winding om Bod ee eek MPR ectifier Bridge Throttle switch Inverter unit stepping motor Charging adjustor ock of electrical Dra Ignition winding Triggering winding High voltage Olivine 019101010 Da oe u u ec 2 stag Oe 2 Service information 2 1 The importance of proper servicing Proper servicing is essential to the safety of the operator and the reliability of th
4. 6 Maintenance standards Engine Part Standard in mm Service limit Cylinder Sleeve I D 2 67 2 68 68 02 68 04 2 68 68 17 Piston Skirt O D Piston to cylinder clearance Pin bore I D 2 68 2 68 67 97 67 99 0016 0023 0 040 0 060 18 002 18 008 2 68 67 62 0047 0 12 18 042 Piston pin O D Pin to piston clearance 708 709 17 990 18 000 0001 0071 0 002 0 018 709 17 95 0003 0 080 Piston ring Ring width Top Second Ring side clearance Top second Ring end clearance Top second 1 420 1 440 1 420 1 440 0 02 0 06 0 150 0 350 1 32 1 32 0 15 1 0 Connecting rod Small end I D Big end I D Big end oil clearance Big end side clearance 7089 7093 18 006 18 017 1 182 30 015 30 025 0018 0024 0 046 0 060 0177 0276 0 45 0 70 0 711 18 07 1 184 30 07 0 12 0394 1 0 Crankshaft Crank pin O D 29 960 29 975 29 90 Valve clearance Intake Exhaust Stem OD Intake Exhaust Vessel I D Intake Exhaust Clearance of valve and vessel Intake Exhaust Seat width Intake Exhaust 0039 0008 0 10 0 02 0059 0008 0 15 0 02 215 216 5 46 5 48 215 5 45 5 47 216 217 5 500 5 518 0008 0023 0 020 0 058 00 0027 030 0 068 031 047 0 8 1 2 211 5 35 211 5 35 219 5 56 0039 0 1 0047 12 079 2 0 Valve spring Free Length Intake Exhaust 1 20 30 5 1 14 29 Cam whe
5. Float chamber installation Float Fuel drain bolt of fuel cup Reassembly Reassembly Check for smooth Make sure there is no fuel movement after leakage after installing installation x Bolt of float chamber Reassembly Make sure there isn t any fuel leakage after assembly Stepping motor Measuring the resistance of stepping motor leading wires Specified 1and3 45 55 resistance 2and 4 45 55Q Replace the stepping motor if the resistance value exceeds the specified range 26 6 Control panel charging adjustor and inverter unit 6 1 Disassembly and assembly Charging adjustor Control panel 6 2 Inspection A Smart Throttle switch There should be continuity between both poles of the switch when placed in the on position If not replace the switch B Ignition Module 3 in one switch Pull out 10P connector plug from the ignition module Connect an ohm meter to ground and measure the resistance in the various 10p connector pins to measure the resistance Use the following chart for reference Color Circuit unit Specified resistance value Blue Primary ignition coil 0 8 1 3 Q It is not lit under the condition that oil position is Orange Low oil alarm normal Yellow Trigger coil 80 130 2 Kelly Grounding wire Put through Green Ignition device power coil winding 0 26 0 28 Q Engine fire extin
6. Tightening bolt of rocker arm base M6X0 75X33 14 75 17 0 20 23 Adjusting nut of rocker axis M6 X0 75 7 4 8 8 10 12 M5 bolt nut 4 4 5 9 6 8 M6 bolt nut 5 9 7 4 8 10 Item Thread dia X pitch Standard torque M8 bolt nut 14 8 17 0 20 23 M10 bolt nut 40 6 44 3 55 60 Note Use standard torque values for fasteners that are not listed in this table 2 8 Troubleshooting A General symptoms and possible causes Cause s Remedy Engine does not start or hard starting Carburetor float chamber contains stale gasoline or no fuel reaches carburetor Drain old fuel clean and or replace Fuel tank tube clogged Inspect Fuel filter clogged Clean Carburetor failure Clean and or replace Spark plug cap disconnected Install securely Ignition coil failure Inspect and replace Spark plug failure Inspect and replace Oil level switch Low oil alarm failure Inspect and replace Igniting device failure Inspect and replace Pulse coil Trigger failure Inspect and replace Choke air inlet not controlled properly The position can be full open or half open Engine speed does not stabilize too high or too low Carburetor failure Adjust and or disassemble and clean Throttle control motor stepping motor failure Inspect Generator failure Troubleshoot Inverter unit failure Troubl
7. coil Replace charging adjustor Check repair wiring harness of alternator and change stator 16 3 MAINTENANCE 3 1 Maintenance schedule Regular service period Each use First month Every 3 Every 6 Every year or Item perform at every indicated or 10 Hrs months or months or 300 Hrs month or operating hour interval 50Hrs 100 Hrs whichever comes first Engine Oil Check Replace Air cleaner Check Clean Spark plug Clean Adjust Spark catcher Clean Valve clearance Check Adjust Fuel tank and filter Clean Fuel line Check Every 2 year Replace if necessary Note Interval operating time in normal troubleshooting When it is used in dusty place filter should be cleaned every 10 hours or everyday Maintenance should be carried out by the qualified technicians 3 2 Engine oil 3 2 Engine Oil A Checking Oil Level Engine should be shut off and generator be on level ground when checking the oil level 1 Remove the oil dipstick check oil level f Upper limit amp Screw the dil stick tightly then unscrew it 17 2 Add the proper viscosity engine oil to the upper limit if oil level is low Be careful to over fill B Changing engine oil 1 Remove the oil dipstick and unscrew oil drain plug to drain used oil 2 Replace the drain plug and secure tightly 3 Add the proper viscosity oil to the u
8. gasket B Check if there is any Reassembly damage in the insulator Check if there is any block before assembly damage in the gasket before assembly 24 5 2 Stepping motor disassembly and reassembly stepping motor stepping motor base fork spring disassembly hold it tightly for fear that the spring will lose when it is disassemblied fork spring fuel control lever 25 5 3 Carburetor disassembly and reassembly NOTE With the exception of changing the main jet no adjustments modifications or other maintenance is permitted on EPA and CARB certified engines This includes any Kipor generator ever sold in North America This drawing is for information only Air stroke rod FO Fork spring Assembly of accelerator Restorating spring of air choke Accelerator piece pi Adjusting screw of oe the mixture ratio Ba re GS Idle adjusting screw ad J Reassembly A DA SS Inspect the abrasion of the eke aes Stopper of front head then install it ee NEG 5 channel lt 2 E a lt y Needle base Main nozzle i at Reassembly Oil control needle Clean channels with compressed Reassembly air before installation Inspect the abrasion of the head check if it is a proper direction and the action of spring then install it Main jet Reassembly Clean channels with compressed air before
9. sun 34 5 1 Carburetor removal and installation eceesceesesseeceeeeeseecseeseaeeeseesseeseeeeeaeeeseetsaeeeaes 34 5 2 Stepping Motor disassembly and reassembly e ceeceeeceeeceeeeeeeereeeeeeeeeeeeeeeseeeeneeeaes 35 5 3 Carburetor disassembly and reaSSOMby ccceceeeeeeeeeeeeeneeeeeeeeeeeeaeeeeeeseeeeeeeeeeens 36 6 Control panel charging adjustor and inverter Unit eceeeeeceeeeeeeeeeeeeeeeeeeeneeeeeeeeeeeeneees 38 6 1 Assembly and disassembly 0 0 eee eeeceeeneeeeeeeeeeeeeeseaeeeeeaeeeeaeeeseaeeessaeeseneeeseneeessaeeeeaaes 38 GZS SOCOM oer se AE E E A E E AY 38 7 Housing group fuel tank assembly and disassembly 0 eee eeeeeeeeneeeeeneeeeeeeeteneeeesaeeeens 41 8 Generator ignition coil ANC trigger oo eee eee eeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeteeeeeeeeeaeeeeeteeeeeaeeeaeeees 42 Bl GEMCN ALON eea eae cate Foca la re tale cotada cassis lotalets fa late AAA AAEE 42 8 Zigntion COMA MOG Ses ase cse se eG ee i dt a a eC nut 43 1 SPECIFICATIONS 1 1 SPECIFICATIONS Dimensions and weights Model KGE3000 3500Ti Length 27 in 686mm Width 16 7 in 425mm Overall height 19 9 in 495mm Net weight Engine 132 Ibs 60 kg KG205 Type 4 stroke overhead valve single cylinder Displacement in cc 12 0 196 Bore x stroke in mm 2 68 x 2 13 68x54 Horsepower 4 0 3600 rpm Compression ratio 8 5 1 Cooling system
10. KIPOR KIPOR POWER GENERATOR SHOP MANUAL SINEMASTER DIGITAL GENERATOR KGES3000Ti Preface This manual covers the construction function and servicing procedure of the KIPOR KGE3500Ti and Coast Distribution model KGE3000Ti generators This manual is principally concerned with the generator specifications function troubleshooting and repair There is a separate manual to cover engine overhaul which includes the starting systems Careful observance of the instructions contained in this manual will result in safe and quality 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 KIPOR POWER CO LTD reserves the right to make changes without incurring any obligation whatever No part of this publication may be reproduced without written permission Table of Contents Specifications 2 3 ees oe a oe et attendee tne 3 Dro SPO CHICANOS 2 aces ca Aas dace hada cess date aoaeiaa aE EE A AE E A EEEE EA EE i EEEE ETATER 3 12 UA AGE D1 SUNOS ree gaa ta ta A dtl a a Hal i ai 4 1 3 Performance Curves 0 0 eecceecceceseeeeeeceeeeneeeneeeneeaeeeseneeesaneneaeessaneneaseneneeesnneneneenenaeetsas 7 2 DELVICE IMOTMALION scorch iach caceceet tel Sacek E duc dude cece ounces A 8 2 1 The importance of proper Service ooo eeeeeeeeeeeeneeeeeneeeeeeeeeeeeeseaeeeesaeeseeeeteeeessaeeeeaaes 8 2 2important
11. all the filter element and close the service door Filter element subassembly Air filter cover Blow the innerr side of air filter element using the compressed air 19 Attention E Don t operate the generator without the filter element in place or serious engine damage may result 3 5 Spark Plug Servicing 1 Remove the spark plug cap and use a spark plug wrench to remove the spark plug 2 Check the condition of the porcelain insulator Replace the spark plug if it is chipped or cracked 3 Remove carbon or other deposits with a stiff wire brush Check if the sealing washer is damaged 4 Check the resistance of the spark plug and replace it if it is not within the specified resistance value Resistance of spark plug 3 9K 2 5 Use a feeler gauge to check the electrode gap Adjust the electrode to the following specification by carefully bending the side electrode to the specified value Clearance of spark plug 024 031 in 0 6 0 8mm Standard spark plug F7RTC 20 6 Reinstall the spark plug and screw it tightly after regulating the specified torque is 18 44 22 13 ft lbs 25 30 N m 3 6 Adjusting valve clearance Attention Valve adjustment should only be performed on a cool engine 1 Remove valve cover Gasket of cylinder head cover f cylinder head cover cae A Sy ae 2 Pull the
12. arts and lubricants or their equivalents Parts that do not meet Kipor s design specifications may damage the engine Use the special tools designed for the product Always install new gaskets O rings etc when reassembling components Clean parts in cleaning solvent upon disassembly Lubricate any sliding surfaces before reassembly After reassembly check all parts for proper installation and operation Many screws used in this machine are self tapping Be aware that cross threading or over tightening these screws will strip the threads and ruin the hole Use only metric tools when servicing this engine Metric bolts nuts and screws are not interchangeable with non metric fasteners The use of incorrect tools and fasteners will damage the engine Electrical precautions Hold the connector body to disconnect the connector Do not disconnect by pulling the wire harness To disconnect the locking connector be sure to unlock first and then disconnect Check the connector terminals for bend excessive extrusion missing terminals or other abnormalities before connecting the connector To connect insert the connector as far as it goes If the connector is a locking type be sure that it is locked securely Check the connector cover for breakage and check whether the connector female terminal is not opened excessively Then connect the connector securely Check the connector terminal for rust Remove the rust using an emery pape
13. d spark _ Spark plug gap or replace a new plug gap spark plug 4 Normal Check for blockage of the main jet_Clogged and holes of carbunetor v Not clogged Disassemble and clean Abnormal Tighten the nuts securely or install Check for paper cushion of air intake a new carburetor heat insulator or and heat insulation of carburetor gasket Normal Abnormal Check if the gap of valve is correct Check the cylinder compression Check if it exists too much carbon Normal in combustio chamber Check the piston piston ring and Perform the throttle control system cylinde for wear and damage troubleshooting G Smart throttle Problems 1 Engine speed is too high hunting or too low Abnormal Perform the generator ene EAS Guip troubleshooting following the Normal instruction of NO or low AC output Check control motor for throttle _Abnormal Replace the control motor for valve throttle valve ii Normal Replace the inverter unit 2 Smart Throttle system does not work under no load engine speed does increase after connecting load with Smart Throttle system ON Abnormal Check the AC output Perform No or low AC output roubleshooting y Abnormal Check the throttle control motor
14. e P Reassembly j Stator Clean the dirty and LA te oil stain on the tape surface of rotator before installation Nut of flywheel f Fan M14X1 5 Q amp Q p 80 90 N m Fixing board of chuck wp Trigger 7 Semicircle key lt oe 2 a Reassembly Ignition coil oS OQ Check if all installed l l aK E properly be careful noti Wire holding board to miss any parts Bus seal ring Rope clutch B Inspection 1 Ignition winding Measure the resistance between green wire and olive wire Resistance value 0 26 0 28 Q 2 Outer use charging winding Measure the resistance between two blue wires Resistance value 0 12 0 15 2 3 Built in charging winding Measure the resistance between two purple wires Resistance value 0 19 0 21 Q9 4 Sub winding Measure the resistance between two white wires Resistance value 0 12 0 14 2 5 Main winding Measure the resistance between three black wires 120V 230 240V Resistance value 0 8 1 1 2 3 3 3 5Q 30 8 2 Ignition coil and trigger A Disassembly and reassembly B Inspection 1 Ignition coil With an ohmmeter check the resistance between the two wires going to the coil primary resistance 0 8 1 3 2 Check resistance between one end of primary ignition coil terminals and spark plug cap to measure sub resistance of ignition coi
15. e generator Any error or oversight made by the technician while servicing can easily result in faulty operation and or damage to the equipment or injury to the operator WARNING E Improper servicing can cause an unsafe condition that can lead to serious injury or death E Follow the procedures and precautions in this shop manual carefully Some of the most important precautions are stated below 2 2 Important safety precautions Be sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and safety equipment When performing maintenance or repairs be especially careful of the following e Read the instructions before you begin and be sure you have the tools and skills required to perform the tasks safely e Be sure that the engine is off before you begin any maintenance or repairs This will reduce the possibility of several hazards Carbon monoxide poisoning from engine exhaust Burns from hot parts Injury from moving parts e Do not run the engine unless the instructions tell you to do so Keep your hands and clothing away from rotating parts e To reduce the possibility of fire or explosion exercise extreme caution when working around gasoline Use only a nonflammable solvent not gasoline to clean parts Keep cigarettes sparks and flames away from all fuel related parts 2 3 Service rules 2 4 Use genuine KIPOR or KIPOR recommended p
16. el Cam height Intake Exhaust I D shaft bore 1 09 1 10 27 63 27 91 1 09 1 10 27 68 27 94 1 08 27 34 1 08 27 34 Camshaft O D 550 551 13 966 13 984 553 13 92 Valve lifter I D shaft bore 313 314 7 96 7 98 310 7 87 Crankcase cover Camshaft Bearing D 550 552 14 000 14 027 553 14 05 Cylinder block Valve lifter I D Camshaft Bearing 1 D 315 316 8 000 8 015 550 552 14 000 14 02 7 317 8 06 553 14 05 2 Spark plug Clearance 024 031 0 6 0 8 Ignition coil Resistance Primary side Second side 0 8 1 30 15 21kO Pulse coil Trigger Air gap Resistance 020 030 in 80 1300 0 5 0 75 Starting relay Resistance 3 8 4 10 Generator Standard 2 Service 120V limit Ignition coil Resistance Yellow Green Green 0 26 0 28 Part Item Type Outer charging winding coil Resistance Blue Blue 0 12 0 15 Inner charging winding coil Resistance Purple purple 0 19 0 21 Sub winding coil Resistance White White 0 12 0 14 Main winding coil Resistance Black Black 0 8 1 1 2 7 Torque values Tightening torque Ft Ibf N m Connecting rod bolt M7 10 3 11 8 14 16 Cylinder head bolt M8 x 60 20 7 23 6 28 32 Spark plug M14x1 25x19 18 4 22 2 25 30 Crankcase cover M8 x30 14 75 17 0 20 23 Flywheel nut M14X1 5 59 0 66 42 80 90
17. eshoot Valve clearance misadjusted Adjust Carburetor replacement parts are not available No adjustments or overhaul is permitted under current EPA CARB guidelines 10 B Hard starting If the engine does not start or is hard starting after reassembly check to see whether the throttle valve is at the full open position Check the fuel level in the tank No tuel Add fuel and restart the engine J Sufficient fuel Loosen the drain screw and Check whether fuel reached the carburetor and check oil level Abnormal Check for blockage of the fuel tube fuel filter or fuel pump Normal Check for blockage in the carburetor port and nozzle Dry Remove the spark plug and Check for wet or fouled electrode Wet Clean the electrode and restart taking care that the choke is not closed too much If flooding is severe check the carburetor float valve No spark or weak spark Perform the ignition system troubleshooting Perform spark test Good spark Install a compression gauge in High cylinder Check for carbon deposits in the the spark plug hole and check compression combustion chamber the cylinder compression by pulling the recoil starter rope Low cylinder Check the valve clearance several times compression Check for worn piston piston ring I Normal compression or cylinder In
18. essary 5 Properly install seal cushion and filter element and tighten the nuts between fuel switch and the fuel tank 22 4 Air Filter and Muffler 4 1 Air filter Disassembly and assembly Carburetor Install make sure that gaskets have no damages and bendings and pay attention to inner and outer sides 4 2 Muffler Disassembly and assembly Muffler syphon assembly Clean the carbon inside muffler syphon using the brush before installing Fireproofing cap assembly Bo Clean the carbon using lt the brush before installing Exhaust pipe gasket Muffler gasket Muffler assembly knock it to remove carbon inside by using rubber muffler hammer before installing 23 5 Carburetor Attention E Loosen the gasoline drain bolts before disassembly to drain fuel in the carburetor E Smoking and any source of combustion are strictly forbidden in the process of disassembly 5 1 Carburetor removal and installation Carburetor gasket A Reassembly Check if there is any damage in the gasket before assembly Rope of air choke Air choke weldment Gasket of Air filter bottom case carburetor Air intake pipe gasket Reassembly Check if there is any damage in the gasket before assembly Insulator block of Carburetor carburetor assembly Reassembly Carburetor
19. fuel tank is enough No fuel Enough fuel 4 g Check if the fuel switch and filter are choked Choked 4 Unchoked Check if the oil feeding pipe is checked Choked 4 Unchoked Check if main nozzles in the holes of carburetor are choked Choked Unchoked A Check the paper cushion of air inlet pipe and heat insulation and sealing of carburetor Abnormal gt Y Normal Measure compression of cylinder Abnormal 4 Normal Check clearance of trigger Abnormal AA control system of throttle valve Perform fault inspecting and repairing 13 Add oil and restart Add Fuel and restart Clean the fuel switch and filter Clean or change the oil feeding pipe Disassembly and clean Tighten the nut or change paper cushion heat insulat on block 1 Check if the clearance of valve is proper 2 Check if it accumulates too much carbon incombustion chamber 3 Check abrasion of piston and piston ring and cylinder Rearrange clearance of trigger F Engine speed does not increase or stabilize Check the air cleaner Clogged Not clogged Clean the air cleaner Abnormal Check the valve clearance gt Readijust valve gap it Normal Remove the spark plug and check Abnormal Clean electrodes and adjust the the electrodes for carbon an
20. guishing switch The Ignition switch is put through when it switches Red one foot on otherwise it will disconnect Unf Ne ROR no Blue Orange Yellow KellyGr en Red 2 C Ignition switch Check connection between each group terminal the results should agree with the states listed in the following table otherwise it should be replaced 2 1 D D D D D OFF o e ae ae ON o o 3 2 START e D Rectifier Use the F gt item of instrument to test connection between each group feet of rectifier plus voltage falls the results must agree with standard listed in the following table Positive lectric pen Negative Electric pen Block Block Block 2 Connect Block Block 3 Connect Connect Connect 4 Connect Block 1 Negative terminal 2 AC terminal 4 AC terminal 3 Negative terminal E Charging adjustor Start the engine and disconnect the wire of charging adjustor with two electrodes of the battery then measure the voltage between output terminal of charging adjustor and grounding wire DC charging voltage 13 14V output anode gray AC input purple Grounding Kelly AC input purple 28 7 Housing group and Fuel tank Housing weldment Housing door weldment Sheath of fuel Fuel tank tank Inle
21. l Sub resistance 15 21KQ ERS 31 2 Trigger Test the resistance between the trigger wires Resistance of trigger 80 130 2 Adjustment Adjust the clearance between trigger and salient of the rotor 0 020 0 030 in clearance of trigger ae 0 50 0 75mm Insert the gauge between the salient of the trigger and the rotor to measure the clearance If it is not within the specified range readjust the trigger to the recommended clearance 32
22. of the three tests fail the problem is either a damaged wire harness or a defective alternator I No DC output 2 Ste engm seed nanma Abnormal _ Perform the throttle control system troubleshooting Engine speed 5500 100 min rpm Smart switch OFF Normal Check the DC output enone Replace the DC receptacle Normal Check the ry Abnormal Rectifier is faulty Replace the rectifier Normal Measure the resistance between the blue DC coil terminals of the rectifier 4P connector Resistance value 0 12 0 15 Q Abnormal Check the wire harness input line replace the stator Normal Rotor lose magnetism replace rotor 15 J Engine will not start Electrically Measure the voltage accumulator Check the ignition swi Moa Abnormal Replace the ignition switch of Abnormal Change a new accumulator tch Normal Check the starting rel F Eau Replace the starting relay Normal Normal Check the starting motor Check repair or chan main harness wire ge K Starting Battery Will Not Hold a Charge Check ignition switch Anormal Normal Check charging adjustor Abnormal Normal Measure resistance value of Abnormal charging winding ad Resistance value 0 19 0 21 Q Normal Check repair or change wiring harness Abnormal Replace the starting motor Replace ignition
23. pper oil limit level 4 Reinstall the dipstick and screw it tightly 3 3 Inspection of the Oil Alert Switch 1 Disconnect the orange connection of the oil alert wire when engine is running and ground one end to the engine block as shown below to ensure that the engine will stop when the oil alert lamp is lit NOTE On early models the oil alert connection is in the back of the generator on the opposite side of the service door O ERU Q i Aii i HH Zs q Lead of ignitor Lead of oil alarm Ground through the case of engine 18 3 Stop the engine and disconnect the orange wire of the oil alert after insuring that the engine oil is at the proper level Test the conductivity between the end shown in the figure and the case of engine No conductivity indicates a normal condition AN T Lead of ignitor Lead of oil alarm 4 Drain all the engine oil in the engine repeat the test The switch is working properly if there is normal conductivity 3 4 Air Filter Maintenance 1 Open the service door 2 Open the cover of air filter and take out the filter element 3 Blow the inner side of filter element using compressed air or lightly knock it to remove dirt If any dirt remains change the element Be sure to use a genuine Kipor element to maintain a proper seal and avoid engine damage 4 Reinst
24. r or equivalent material before connecting the connector Set the harness clips in the specified places of the frame securely and secure the wire harnesses Clamp the cables securely e Clamp the wire harnesses securely so that they do not interfere with the rotating parts moving parts and hot parts e Route and connect the wire harnesses properly Be sure that the harnesses are not slack twisted or pulled overly taut e Route the wire harnesses properly so that they do not contact sharp edges and corners and the end of the bolts and screws on the body e f a wire harness must contact the end of the bolts or screws or sharp edges and corners protect the contact part of the harness with a loom or by winding with electrical insulating tape If the wire harness has a grommet set the grommet securely e Take care not to pinch the wire harnesses during installation of a part If a wire harness has damaged insulation repair by winding with electrical insulating tape e When using an electrical tester like a volt ohm meter or clamp on meter read the manufacturer s operating instructions carefully before operating the tester Be sure that the tester battery is fully charged and the meter is functioning properly 2 5 Serial number location The engine serial number is stamped at the underside of engine side cover Refer to this number when ordering or making technical inquiries Engine serial number Engine serial number 2
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26. stall the spark plug securely Restart the engine according to the starting procedure e Cylinder compression check 1 Remove the spark plug cap and spark plug 2 Install a compression gauge in the spark plug hole Pull the recoil starter rope several times with force and measure the cylinder compression Cylinder compression 0 45Mpa 600rpm e Ignition system fault inspecting and repair Spark Test a Remove the spark plug b Install the spark plug onto spark plug cap c Turn the ignition switch of engine to the position ON Then ground the spark electrode to the cylinder head cover and pull the start motor rope to check if sparks jump across the 11 electrode Warning E Do not pull the recoil starter rope while touching the high tension wire with a wet hand High voltage is generated which is dangerous Be sure to ground the spark plug and hold the plug cap with an insulated pair of pliers to perform the spark test E Make sure no spilled fuel is anywhere on the engine and no fuel is on the spark plug i Keep sparks and any other combustible source away from the spark plug hole C Engine does not start with sufficient oil in the crankcase Measure the spark plug gap and perform the spark plug Gap 0 6 0 8mm yNo spark Perform the spark test again using Good spark a new spark plug gt 4 No spark Replace the spark plug k Perform test using a new por
27. starter rope gently and set the piston in top dead center the scale of starting wheel should align with the sign A on the air guiding cover y mark scale VY a 4 Ze 214 S Y WA G I Yu g UING o 3 Insert a feeler gauge into the gap between rocker and valve to measure the valve clearance Intake 0039 0008 in 0 10 0 02mm Valve Clearance Exhaust 0059 0008 in 0 15 0 02mm 21 4 If adjustment is necessary proceed as follows a Hold rocker axis using the wrench and loosen the lock nut b Loosen the lock nut of rocker axis to gain the specified intake and exhaust valve clearance c Hold rocker axis using a wrench and tighten the lock nut d Check the clearance of valve after adjustment 3 7 Fuel filter and fuel switch maintenance rr 7 Fuel tank Filter seal cushion ae ho Fuel element Fuel switch Attention E Keep smoking materials and any open flames away during fuel system maintenance E Make sure that there is no leaking fuel after service 1 Drain all fuel from the tank and carburetor and remove the fuel tank 2 Loosen the nuts between fuel switch and fuel tank and remove the filter element 3 Turn the fuel switch to the open position Clean it with a suitable solvent then blow dry with compressed air 4 Remove any foreign material from the fuel filter and insure the filter net is undamaged Replace if nec
28. t capacity 13L Reassembly Clean the squalidity or water in the bottom before assembly Door lock components Gasket o framework Air drain bar Oil drain plug Fixing board of accumulator Fixing bolts of lt g accumulator aa Chassis assembly Accumulator Damping cushion Reassembly Check if the damping cushion is aging or rupture before assembly Dottom base Damping cushion of Fuel tank cover Reassembly Check if air vent is blocked before assembly Glass of float finda Handle sheath Window fixing Oil dipstick Assembly Check if the float is rotating smoothly before assemly Filter net of fuel tank Reassembly Check if the mesh is blocked or damage before assembly Reassmbly Check if filter element is blocked or damaged and clean filter element and oil switch before assembly Fuel feeding pipe Reassembly Check if there is rapture and aging before assembly Replace every two years Framework weldment Bend connecting board Control panel Front cover Rubber sleeve of handle Fixing board of damping Weldment of Pao cushion handle Inverter unit ss ee board of moduel Starting relay 29 8 Generator ignition coil trigger 8 1 Generator A Disassembly and Reassembly EAE Rotator S ator pin gt e
29. tfire Good spark 4 No spark Disconnect low oil alarm and perfom Good sparky Replace the oil level switch spark plug test Replace the portfire 4 No spark Abnormal Inspecting the resistance value of gt Replace the stator of altemator alternator ignition coil Normal A i Inspecting the resistance value and the eg Replace the trigger or adjust clearance of trigger the clerance of trigger y Normal Abnormal Inspecting resistance value of ignition y Reo he igniti il coil and high tension cable and insulation aa emacs of high tension cap Normal Inspecting and repair or replace 12 Drain all the oil disconnect wire of low oil alarm and measure linkage of output of low oil alarm and the ground D Engine oil level is low but engine does not stop Disconnect gt 4 Connect Connect the wire of low oil plugs then measure orange wire and the ground and disconnet portfire connector linkage of alarm 4 Connect Portfire fault replace portfire Disconnect Replace the low oil alarm or repair it Wiring harnessfault replace E Engine starts but then stalls throttle is installed in proper position the engine oil alarm gives a alarm Check if engine oil is enough and see if Oil alarm 4 Enough engine oil Check if the fuel in
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