IG2600HP Service Manual
Contents
1. 46 Stepping motor Measure the resistance of stepping motor connection to the inverter Standard resistance Between land 3 45 550 Between 2 and 4 45 550 Replace the stepping motor if the resistance excesses the above range MON gt a I NS WAS Y Sa EN 47 7 Control panel 7 1 Removal Installation Front cover shell Coontrol panel SS n CS el fi Bs y se a aa 4 gt ny 4 4 res gt BE N 5 u Plug in A Capacitor pressure plate Pi Front cover Capacitor Capacitor pressure plate 48 Smart switch DC receptacle Kant Ng P e 7 2 Inspection a Control panel AC receptacle Rectifier a AC receptacle gt S Ignitor RE a f pes SUN EEN y Check the electrode contact disk inside receptacle if it is burnt or the color changes replace for it O DC receptacle Connect both terminals of the receptacle with a jumper wire to short There must be continuity between the lead wire terminals with the circuit protector ON Replace the DC receptacle if there is no continuity Smart switch There should be continuity with the switch ON and no continuity with the switch OFF 49 O ignitor ignition module Pull off the 10P receptacle from ignitor measure t2. 42 6 INTARE SYSTEM aan A AAA AAA 43 6 1 AIR FILTER REMOVAL AND INSTALLATION a 43 6 2 CARBURETOR REMOVAL AND INSTALLATION a 43 6S INSPECTION usuta eaen aa Sua ba lu ubasta reiben het 46 1 SONTROL P ANEE vii El 48 7 1 REMOVAL AND INSTALLATION n ana 48 7 2 INSPECTION OF COMPONENTS I u L naa 49 8 HOUSING FUEL TANK GUIDE PLATE BOTTOM PLASTE _ uuersnneenerssnnneneennnennenen nennen 52 8 1 HOUSING DISASSEMBLY AND REASSEMBLY a 52 8 2 FUEL TANK ASSEMBLY 2 34 Qu ugh ae kas annahm faves RR dee nit Casa dran 53 8 3 GUIDE PLATE BOTTOM PLATE uusrssnsesnssennnnnnnnnnnennennnnennnnnnnnnenennnnnonsnnnnnnnnnnnennnn nn 54 8 4 BOTTOM PE TE IG2600H Hu ee sea leihen 55 9 RECOIL STARTER AIR CONDUCT COVER GNTION COLL uuunnsnsneenensnnnnnensnnnnnnn nenn 56 9 1 DISASSEMBLY AND REASSEMBL uuussssennnnesnennensnnnnnennnnnnnnnnpnn nenn onnn nn nnn nennen nn 56 9 2 RECOIL STARTER INSTALLATION sten hen nnnnennnnnnnnnnennnnnn nn 58 9 3 IGNITION COIL INSPECTION urus t it 61 10 ALTERNATOR TRIGGER UA u 62 10 1 AETERNATOR cripta A leeren a iba 62 102 INSPECTION SEES TE Re ef eee E Mu u ua usa 62 10 3 TRIGGER ADJUSTMENT nf A usai e daa ea nennen naar 63 11 VALVE COVER ROCKER ARM L f u 64 11 1 DISASSEMBLY REAS
3. 72 8 966 8 975 8 920 Decompression block Check the return spring for damage and weary make sure the decompression block could perform well Decompression block Return spring 73 13 CRANKSHAFT PISTON 13 1 Disassembly Reassembly Valve spring seat Valve spring Oil seal of inlet valve pipe Inlet valve pipe Assembly Install the big semicircular label side of top Cylinder block piston towards the inlet valve Towards inlet valve Oil seal Crankshaft Assembly Pay attention not to damage the oil seal push it until the bearing touches the bearing seat bottom Drive gear Exhaust valve seat Be Inlet valve Exhaust valve Assembly Check the conical face for Connection rod cover damage and carbon deposits A C nnaci n ted bal before installation M7 14 16N m Don t mix the inlet or exhaust alve Conical face diameter Inlet valve 224 Exhaust valve 023 74 Crankshaft timing gear 13 3 Piston Manufactory label Ek Piston Piston pin Piston pin clip ring Assembly Set the front end in the piston groove clamp 4 the other end with sharp nose pliers Install the ring clip by revolving it pay attention that the opening should not face the gap of piston pin hole Te Na LAR Connection rod NN Assembly Put the long side of the big end towards 0 A Y Y to the semicircle label install the big
4. 6 Intake System Caution E Loosen the drain bolt and drain out fuel before disassembly E Keep heat flame and sparks away 6 1 Disassembly Installation of Air filter Breather tube J Na lt In j f F VA dy Carburetor gasket T H Installation to ik Check the gasket for curve Tigh s 3 or damage pay attention to a the inside or outside direction Fine filter Air filter shell Rough filter Seal gasket Air filter cover 43 6 2 Disassembly Installation of Carburetor Inlet pipe gasket EN Installation Check the gasket for curve or damage pay attention to the inside and outside direction Craburetor gasket Installation Check the gasket for qe damage before installation RO Carburetor stud Carburetor insulation block Installation A inlet pi Check the insulation Oil inlet pipe block for damage before installation eDisassembly Installation of Stepping motor aa Stepping motor cover LA Throttle Lever x Fork Ey gt J ORM Qe Wa o Bea IS N N y t an Ton EN Stepping motor CE Fork Spring 4 UL i ws Y HN e Stepping motor seat d U N Stepping motor bracket EA Fork Spring a Disassembly hold the spring firmly Sq E e r Fork O Disassembly Installation of Carburetor Choke valve Fork Fork spring Choke valve plate Idle adjusting cap de u Carburetor block mixture adjusting screw sealed yl N
5. WUXI KIPOR POWER PRODUCTS CO LTD IG2600 IG2600P IG2600HP SHOP MANUAL EPA CETL Certified Models Kipor Power Systems Inc Revision 1 June 2011 Preface This manual covers the construction repair and servicing procedures for the KIPOR IG2000 and IG2000P Model generators Some models were sold with an H suffix designating an integrated handle The manual is applicable to EPA and CETL models Through the 2011 model year CARB certified units have not been offered Careful observance of these instructions will result in better safer 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 Wuxi Kipor Power Co Ltd reserves the right to make changes without incurring any obligation No part of this publication may be reproduced without written permission CONTENTS PREFACE oi r HA RR Innen 1 CONTENTS anu er AR ne nn redet 2 1 SPECIFICATIONS WIRING DIAGRAM n nenn nenn nn nn nn 4 AAP SPECIPIGATIONS uri a 4 1 2 PERFORMANCE CHARACTERISTICS a 5 1 3 PERFORMANCE EURVES Hrn a tau agama umasa saham a Maa 7 1 4 DIMENSIONAL DRAWING u n anu 9 1 S WIRING DIAGRAMS con iiiar of ein diia lid 11 2 SERVICE INFORMATION aaa SS Tasa a uQ a u aa au ua a ah q u aS 13 2 1 THE IMPORTANCE OF PROPER SERVICING a
6. p p Valve clearance misadjusted Readjust 18 3 2 Hard starting Check the fuel level in the tank No Tue Add fuel and restart the engine suc fuel Loosen the drain screw and No Add fuel and restart the engine check whether fuel reaches the carburetor Good spark Remove the spark plug and check for wet or fouled electrode Check for blockage in the carbureto port and nozzle Clean the electrode and restart Wet taking care that the choke is not closed too much If flooding is severe check the carburetor float valve No spark or Remove the spark plug and weak spark check for wet or fouled electrode Perform the ignition system roubleshooting ore spark Low cylinder Install a compression gauge and __Compression 1 Check the valve clearance check ylinder compression by 2 Check for carbon deposits in the pulling the recoil starter rope combustion chamber several times 3 Check for valve cone and base 4 Check for worn piston piston ring lor cylinder Normal compression Install 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 800rpm 19 Pressure gauge c
7. reassembly 6 After reassembly check all parts for proper installation and operation 7 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 8 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 may damage the engine 9 Follow the instructions represented by these symbols when they are used 2 4 Electric precautions 1 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 2 Check the connector terminals for bend excessive extrusion missing terminal or other abnormalities before connecting the connector 3 To connect insert the connector as full as it goes If the connector is a locking type be sure that it is locked securely 4 Check the connector cover for breakage and check whether the connector female terminal is open excessively Then connect the connector securely Check the connector terminal for rust Remove the rust using an emery paper or equivalent material before connecting the connector 5 Set the harness clips in the specified places of the frame securely and clamp the wire harnesses 6 Clamp the wire harnesses securely so that they do not interfere with the rotating p
8. Installation Check the gasket for an demage before installation Respirator clapboard 3 Turn the rotor to set the piston at top dead center of the compression stroke Timing line of camshaft driving chain should align with the cylinder head seal Insure the intake and exhaust valve are closed 35 Te labia Exhaust valve Inlet valve Revolving direction Caution E If the intake valve is open turn the rotor again to align the timing line with the cylinder head seal and both the valves should be closed 4 Insert a feeler gauge between the rocker arm and the valve and measure the valve clearance IN 0 10 0 02mm EX 0 15 0 02mm Valve clearance 5 If adjustment is necessary proceed as follows a Loosen the adjusting screw lock nut and adjust the valve clearance by turning the adjusting screw in or out b Secure the adjusting screw with a socket wrench and tighten the lock nut to the specified torque c After tightening the lock nut check the valve clearance again 36 Feeler gauge 6 Clean the liquid gasket of the cylinder block and cylinder head cover Apply the liquid gasket Three Bond 1207B or equivalent to the cylinder block installation surface as shown Cylinder seat Seal gum with 1 5 2mm diameter 7 Install the parts in the reverse order of removal 37 4 7 Fuel tank Fuel filter E Gasoline is highly flammable and explosive You can be burned or s
9. are connected 30 2 Stop engine disconnect oil alarm connector check the connector continuity no continuity is normal Ignitor output terminal Alarm output terminal Check the conduction between the two wires 3 Drain the engine oil and check for continuity Continuity is normal 4 4 Air cleaner service 1 2 Disengage the locking tab by pushing and removing the air cleaner cover 3 Remove the element from the air cleaner case Loosen the cover screw and remove the maintenance cover 4 Clean the element in warm soapy water rinse and allow to dry thoroughly or clean with solvent and allow to dry 5 Dip the element in clean engine oil and squeeze out all the excess oil Excess oil will restrict air flow through the foam element and may smoke at the engine start 6 Install the air cleaner element in the air cleaner case 7 Clean the air cleaner seal and the air cleaner case if necessary Be sure the air cleaner cover seals are seated securely 8 Install the air cleaner cover Be sure that the air cleaner cover seals are set securely 9 Install the maintenance cover securely 31 Fine filter element Filter cover l Tighten bolt P E Rough filter element Wash Dry Dip in engine oil Squeeze firmly Sponge sealing strip Caution A dirty air cleaner will restrict air flow to the carburetor reducing engine performance If the engine is operated in dusty areas clean the air cleaner more often t
10. diaphragm tube replace the tube 4 Check to see whether water or foreign material has been accumulated in the fuel pump If there is water or foreign material accumulated in the pump replace the fuel pump 5 Check the fuel switch and fuel duct blow away the foreign matter with high pressure gas with oil switch turned on 6 After assembly check for gasoline leakage from each part Fuel pump Fuel pipe Diaphragm pipe neh To carburetor To negative pressure port Fuel tank _ Oil switch Fuel pipe 39 4 9 Spark arrestor Caution E Perform maintenance on a cool engine 1 Remove the rear cover 2 Disassemble the spark arrestor from muffler 3 Remove the carbon from the spark catcher steel mesh check for damage and replace if necessary 4 Install the removed parts in the reverse order of removal 40 5 Muffler Caution 5 1 Muffler mg Muffler removal installation must be performed with the engine cold O Disassembly Reassembly Muffler instalation Remove the carbon deposit m slightly by tapping w h a rubber hamber before installation u Muffler gasket Spark catcher installation iV Remove the carbon depost with brush before installation Rearcover Seal strip of rear cover 41 5 2 Exhaust tube secondary air injection valve O Disassembly Reassembly Exhaust tube Secondary air injection valve gasket Second air injection valve AF 42
11. gap 0 5 0 75 Trigger Resistance 80 1300 Alternator Standard Q Parts Item Type 120V Ignition coil Resistance Green YELLOW GREEN 0 26 0 28 Outer charging Resistance Blue Blue 0 12 0 15 winding Vice wining Resistance White White 0 12 0 14 Mai van Resistance Black Black 0 8 1 1 winding 2 6 Torque Values Fastening parts Fastening torque Fastening parts Ep specification Nm Kgf m ti NIT M7 14 16 1 4 1 6 bolt Spark plug M14x1 25x19 25 30 2 5 3 0 Valve gap adjuster s M5x0 5 6 9 0 6 0 9 nut Flywheel nut M14x1 5 80 90 8 0 9 0 M5 bolt nut 6 8 0 6 0 8 M6 bolt nut 8 10 0 8 1 0 Standard torque M8 bolt nut 20 23 2 0 2 3 M10 bolt nut 55 60 5 5 6 0 Note Use standard torque values for fasteners that are not listed in this table 17 3 TROUBLESHOOTING 3 1 General symptoms and possible causes not start or Trigger faulty or trigger clearance Inspect and replace hard starting faulty Spark plug cap loose Install securely Low oil alarm faulty Inspect and replace Igniter faulty Inspect and replace Ignition winding faulty Inspect and replace Throttle opening fault Set in fully closed or half closed position Carburetor faulty Clean or replace Engine speed g Throttle control motor stepping Inspect and replace does not motor faulty stabilize too I rau I F r I nverter unit fau nspect and replace high or too low x
12. mm The 1 2 ring 1 47 1 48 1 37 79 Piston pin outer diameter Standard mm Service limit mm 12 994 13 000 12 950 O Piston pin hole inner diameter Standard mm Service limit mm 13 002 13 008 13 050 O Clearance between piston pin and piston pin hole Standard mm Service limit mm 0 002 0 014 0 080 Connection rod small end inner diameter Standard mm Service limit mm 13 006 13 014 13 077 80 Connection rod big end inner diameter Standard mm Service limit mm 26 020 26 033 26 090 O Crankshaft neck outer diameter Standard mm Service limit mm 25 967 25 980 25 900 81 Connection rod big end side clearance Standard mm Service limit mm 0 1 0 4 0 8 N Oil film clearance of connection rod big end 1 Wipe off the oil on the surface of crankshaft neck 2 Set the plastic wire feeler at the crankshaft neck and install the connection rod Tighten the bolt to the prescribed torque pay attention that don t revolve the crankshaft The tighten torque is 8 to 10N m 3 Disassemble the connection rod measure the plastic wire feeler thickness 4 Replace the connection rod if the clearance exceeds the service limit and measure the clearance again Grind the crankshaft neck if the new cle
13. 13 2 2 IMPORTANT SAFETY PRECAUTIONS a 13 2 3 SERVICE RULES ais licita ii tdi 14 2 4 ELECTRICAL PRECAUTIONS l nn rn cedo na 14 2 5 SERIAL NUMBER LOCATION amp 8 uu 15 2 6 MAINTENANCE STANDARDS U n nennen non 16 2 7 TORQUE VALUES 444 2 NA qaa a oraa T Qata ua d 17 3 TROUBLESHOOTING L AU Su a gah anat a qu uu s esa rer a S Qa awas 18 3 1 GENERAL SYMPTOMS AND CAUSES Ah a 18 3 2 HARBD STA RTING Reli 19 3 3 OQILALARM iO Rs ia 22 3 4 ENGINE STOPS RUNNING n na 22 3 5 ENGINE SPEED UNS TABLU ee tel 23 3 6 THROTTLE CONTROL SYNEM i iit a ei nee deie Eia raara a a a ot 23 IT SMART TAROT TEE NN a da 24 3 3 LOW OR NO AC ORT PUT nasse aeara Ee polera 24 3 3 NODC OUTPINN D e a AAA na 26 3 10 NO PARABRELMOUT PUT 24 ea E E a ige 26 4 MAINTENANCEZ L Ranes 28 471 MAINTENANCE SCHEDULE Mn ne das 28 4 2 ENGINE kO 22 RE ea ai 29 4 3 CHECKING THE LOW OIL ALARM uuusnnssensssnnnnnnesnennensnnnnnennnennnnnn nennen nennen nenn non 30 AA AIR CLEANER Hr AAA A u aus as Stead ede na 31 2 5 SB RK PLUG 2 44 ta 33 2 6 VALVE CLEEARANCE u Rein 35 4 6 FUEL TANK AND FILTER oia ee pen 38 4 8 FUEL PUMP AND HOSES I n nn naa 39 2 3 SP RKARRESTOR uti 40 S EXHAUST SYSTEM alas pas at 41 9 1 MUFELPEERSL a anu AAA a aqa da 41 5 2 EXHAUST TUBE SECONDARY AIR INJECTION VALVE a
14. 5 Assembly of crankcase cover 1 Clear the remaining seal gum on the cylinder block and crankcase cover with cloth 2 Smear seal gum 1207B on the cylinder block sealing face as picture shows 3 Reassemble the crankcase cover in the opposite direction of disassembly Caution Install the crankcase cover on the cylinder block 3 minutes after smearing Revolve the crankshaft if necessary 4 Tighten the crankcase cover bolt slowly screw to the prescribed torque 5 Wait for 20 minutes after installation never refill in oil or start the engine during these 20 minutes Seal gum with diameter 1 5 to 2mm Cylinder block 11 6 Inspection Inspection of oil alarm 1 Stand the oil alarm check the oil alarm output wire and copper earth wire there should be no continuity 2 Bottom up the oil alarm check again there should be continuity 3 Bottom up the oil alarm completely in the oil check the float there should be no continuity 71 Cam height Standard mm Service limit mm 29 026 29 086 28 15 Cam inner diameter Standard mm Service limit mm 9 000 9 015 9 035 x l b lt a 1 e d AN JS d E AS LR d bo ih k a I gt l I q i tp lt D ER q j i ED ED an ae yf HL y EN U Camshaft outer diameter Standard mm Service limit mm
15. 5Mpa 800rpm gt Cylinder Sleeve I D 66 01 66 03 66 115 Piston Piston Skirt O D 65 96 65 98 65 85 Piston Pin bore I D 13 002 13 008 13 05 Piston pin O D 12 994 13 000 12 95 Piston ring Height h 1 47 1 48 1 37 SER Side gap 0 03 0 06 0 15 First air ring Closed entry gap 0 20 0 30 1 0 Thickness t 2 70 2 90 2 5 Height h 1 47 1 48 1 37 a Side gap 0 03 0 06 0 15 Second air ring Closed entry gap 0 20 0 35 1 0 Thickness t 2 70 2 90 2 5 Height h 2 47 2 48 2 37 FR Side gap 0 03 0 06 0 12 Oil ring Closed entry gap 0 15 0 30 1 0 Thickness t 2 70 2 90 2 5 Small end I D 13 006 13 014 13 077 Connection rod Big end I D 26 020 26 033 26 09 Crankshaft Crank pin O D 25 967 25 980 25 9 Intake 0 10 0 02 Valve clearance Exhaust 0 15 0 02 Intake 5 46 5 48 5 4 Valve Stem O D Exhaust 5 45 5 47 5 4 Guide I D Intake Exhaust 5 500 5 512 5 56 Seat width Intake Exhaust 0 8 1 2 2 0 Valve spring Free length Intake Exhaust 30 5 29 Cam wheel Cam height 29 026 29 086 28 15 O D 8 966 8 975 8 92 Camshaft I Camshaft Bearing D 9 000 9 015 9 035 Rocker arm I D 6 000 6 012 6 05 Rocker arm shaft O D 5 972 5 98 5 91 Rocker arm 6 05 Rocker arm shaft I D bore 6 000 6 012 16 Main jet 0 70 Carburetor Float height 16 Indicator switch width 2 circle Spark plug Air gap 0 6 0 7 sq y En Primary side 0 8 1 30 gnition coi esistance EEE 15 21KQ Zr Pulse coil Air
16. Check the throttle control motor Replace the throttle control motor normal Replace the inverter unit 23 3 7 Smart throttle doesn t work with zero load engine speed doesn t increase with smart throttle on and load connected Perform the generato Abnormal Check the AC output roubleshooting following the instruction of No or low AC output Normal Abnormal Check the throttle control motor Replace the throttle control motor Normal Abnormal Check the Smart switch Replace the smart switch Normal I A Check Smart switch connection wire bnorma Repair or replace the wire harness Normal Replace the inverter unit 3 8 No or low AC output Zn j ON Disconnect the load and restart the Is the overload indicator light ON engine or Perform the throttle control system est Norma Stop the engine and check the AC Abnormal ee I Replace the AC receptacle Normal Is the engine speed normal Abnormal Smart switch ON 3200 100rpm OFF 4300 100rpm Disconnect the 6P connector on inverte unit pull the recoil starter with force and measure the AC voltage between the black terminal and white terminal 1 Check and repair stator wire Abnormal _ harness or replace stator 2 Rotor inner magnetism White White gt 1V decreases replace the rotor Normal Replace the inverter unit 24 Inverter unit Main winding Sub winding Measure voltage Phase wire color Black Black B
17. Ignition system E Fill in oil to the demanded level E Use specified UR5 spark plug E Spark plug inspection 1 Disassemble spark plug 2 Install spark plug onto spark plug cap 3 Set the oil switch to the ON position Ground the negative electrode i e threaded part of the spark plug against the shroud and pull the recoil starter rope to check the spark plug You should see a clear spark Ah Warning E Don t pull the recoil starter while touching the high tension wire with wet hands High voltage is generated and very dangerous E Drain the gasoline from the fuel tank and carburetor Pull the recoil starter several times to release the unburned gas in the cylinder with the engine switch OFF 20 Measure the spark plug gap and perform the spark plug test Standard clearance 0 6 0 7mm Perform the spark test again using a Good spark new spark plug Replace the spark plug No spark Remove the control panel Perform Good spark the spark test using a new igniter Replace the igniter No spark Good spark I Check the engine switch Replace the engine switch No spark Good spark Disconnect the low oil alarm and perform spark test Replace the low oil alarm No spark Abnormal Check the resistance of motor ignition winding Replace the motor stator Normal Check the trigger Normal Abnormal Replace the trigger or read
18. SEMBLY 1 na 64 11 2 INSPECTION EL L a a nn neh einer 64 12 CRANKCASE COVER CAMSHAFT DRIVE CHAIN a 66 12 1 DISASSEMBLY aus Ve re ein qapa h kanaa gua 66 12 2 CRANKCASE COVER REASSEMBLY I nenn nennen nn 67 12 3 ROLLER CHAIN REASSEMBLY I nennen nennen nn nennen nenn 67 12 4 CHAIN SUPPORT PLATE PRESSURE PLATE uusrssssennnsnenennnnnennnnen nenn nennen nennen 68 12 5 CRANKCASE COVER ASSEMBLY a 71 12 6 INSPECTION AN u us iii ia 71 13 CRANKSHAFT PISTON AND CONNECTING ROD a 74 13 TDISASSEMIB ir Hr die a a ne tata a Su a 74 13 2 PISTON CONNECTING ROD I a 75 133 INSPECTION aun a ur Ener uQ cee cannes O Mua agree 76 1 SPECIFICATIONS 1 1 SPECIFICATIONS Dimensions and weights Model IG2600 IG2600H Overall length in mm 22 2 564 23 3 590 Overall width in mm 12 6 320 13 330 Overall height in mm 18 3 465 18 9 480 Dry weight Ib kg 68 29 5 70 4 31 Engine Model KG166 Type 4 stroke single cylinder grees camshaft gasoline engine Displacement cm 171 Bore x stroke mm 66x50 Max output KW rpm 3 3 3600 Compression ratio 8 5 1 Cooling system Forced air Ignition system T C I Ignition timing fixed 26 5 B T D C Spark plug UR5 Carburetor Float type Horizontal butterfly valve type Air cle
19. aner Semi dry type twin elements Governor Electronic control Lubrication system Splash Oil capacity L 0 56 Starting system Recoil starter Stopping system Primary circuit ground Fuel type Automotive unleaded gasoline Generator Model KD30 Generator type Multi pole alternator Generator structure Self ventilation drip proof Excitation Self excitation Magnet Voltage regulation system PWM Magnet Phase Single phase Rotating direction Clockwise Viewed from the generator end Frequency Inverter quartz regulation 1 2 Performance Characteristics Model IG2600 162600H Max output AC 2 6 KVA Rated output AC 2 3 KVA Rated frequency 60 Hz Rated voltage AC 120 Rated voltage DC 12V Rated current AC 19 2A Rated current DC 5A Power factor cosp 1 0 Voltage variation rate Momentary Max 10 Average Max 1 5 Average time Max 3s Voltage stability 1 Frequency variation rate Momentary Max 1 Average Max 1 Average time Max 1s Frequency stability 0 1 Insulation resistance Mini10MQ AC circuit protector 11 5A 230V DC Circuit protector 5A Fuel tank capacity 4 6L Fuel consumption g KW h Cat rated load 500 Continuous operating hours Cat rated load 3 Noise level 23 7M NL FL 58 65 dB 1 3 PERFORMANCE CURVES The curves show performance of the genera
20. arance still exceeds the service limit and use the connection rod less than the standard valve Standard mm Service limit mm 0 040 0 066 0 120 Plastic wire feeler 82 Bearing vibration Clear the bearing and dry it check the clearance between crankshaft journal and connecting rod big end by revolving bearing by hands Replace for a new bearing if there is abnormal noise or vibration Clearance bebween crankshaft journal and conmecting rod big and Clearance belween srankehaf journal and connecting rod big end Axial direction Circle direction
21. arts moving parts and the hot parts 7 Route and connect the wire harnesses properly Be sure that the harnesses are not slack twisted or pulled taut 8 Route the wire harnesses properly so that they do not contact with the shape edges and corners and the end of the bolts and screws on the body 9 If a wire harness contacts the end of the bolts screws or sharp edges and corners protect the contact part of the harness with a tube or by winding with an electrician s insulating tape If the wire harness has a grommet set the grommet securely 10 Take care not to pinch the wire harnesses during installation of a part If a wire harness has the damaged insulation repair by winding with the electrician s insulating tape 11 Read the tester manufacture s operation instructions carefully before operation with tester Follow the instructions of the Service Manual Be sure that the battery built in a tester is fully charged and check the meter before inspection using the tester 14 2 4 Serial number location The engine serial number is stamped at the underside of engine side cover Refer to these numbers when ordering or making technical inquiries Serial number 15 2 5 Maintenance standards Engine Part Maint Item Standard mm 3 eure limiting Engine Maximum speed without load 3600 100 rpm Cylinder compression 0 4
22. cating ligh Off 1 Check the parallel output cable on 2 Check the parallel output terminal Jon Check the paralleled I O communication Abnormal Replace the parallel 1 0 ire communication wire Normal Check the paralleled I O communication Abnormal Replace the parallel 1 0 receptacle communication receptacle Normal Replace the inverter unit 4 Maintenance 4 1 Maintenance Schedule Regular service period 1 First Every 3 Every 6 Every Item perform at every indicated Each use th tal month or months or months or year or I AR en un 20 Hrs 50Hrs 100 Hrs 300 Hrs whichever comes first aor de ME di ide A Replace o are ee clean d e Spark plug Ciean adjust e Spark catoher_ Clean Adjust a Valve clearance clearance Check Adjust a Sa Fuel tank and filter element Every 2 year Replace if necessary Note 1 For commercial use operation hours are determined by proper maintenance 2 Service more frequently when operating in dusty areas every 10 hrs or every day 3 Service by KIPOR authorized agency unless correct tools or professional specialist is available Do service according to the manual 28 4 2 Engine oil E Checking the oil level Stop the engine and check the oil level Be sure to have the generator on a level surface 1 Loosen the screws of the maintenance cover and remove the cover 2 Remove the oil
23. e chain is not parallel with cylinder head sealing face adjust the meshing of chain and cam 5 Install the O seal ring into the drive shaft and then assemble the drive shaft Step 4 Pay attention that the opening of drive shaft should upward 6 Install chain pressure plate Step 5 67 Oil alarm Timing mark UM T ss Timing mark on the crankcase block 12 4 Assembly of chain support plate pressure plate Chain support plate 1 Put the upper groove of chain support plate into block press the other end to seize the support plate fully 2 Insert the location pin into cylinder block location hole and align them set the support plate and clip block into cylinder block Adjust the clip block location to align the clip bolt with cylinder block bolt 68 3 Install inner hexagonal bolt and tighten hard Press hard Chain pressure plate 1 Install the spring pin shaft spring and chain pressure plate as the picture shows 2 Insert the spring into block location hole set the chain pressure plate into cylinder block and spring into location hole Pay attention that the spring pin should be inserted as far as location 3 Adjust the block location to align the block bolt hole with cylinder block bolt hole 4 Install the inner hexagonal bolt and tighten it 5 Hold the spring free end to seize the block as picture shows knock the spring pin with copper hammer 69 70 12
24. eedle seat Foam tube k Installation clear foreign i L CS Fuel control needle material with compressed R Installation check the end air before installation dh J A i and spring before installation i eet Le Fuel control needle Main metering jet a B Installation clear foreign material Sealing ring of bowl with compressed air before f installation Pay attention to the e Float pin installation direction 7 Float LY Bowl Sealing ring of carburetor bowl Bowl bolt k wee N Bowl drain bolt is ER IX Installation check for Installation check for 7 SS de fuel leakage ater fuel leakage after WY X 3 gt installation installation au 45 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 Kipor will not supply any carburetor parts other than stepping motors and main jets 6 3 Inspection Float height Place the carburetor on a level surface as shown measure the float height between the float and carburetor block Height 12mm Replace the carburetor if the float height is not correct Float J 12 ALT gen
25. end to piston Clip ring 75 13 3 Inspection Free length of valve spring Standard mm Service limit mm 30 5 29 O Valve seat width Standard mm Service limit mm 0 8 1 2 2 0 N 76 Valve rod outer diameter Standard mm Service limit mm Inlet valve 5 46 5 48 5 4 Exhaust valve 5 45 5 47 5 4 gt NY O Valve guide pipe inner diameter Standard mm Service limit mm Inlet Exhaust valve 5 500 5 512 5 56 FI N L yA CS E P Clearance between valve rod and valve guide pipe Standard mm Service limit mm Inlet valve 0 020 0 052 0 10 Exhaust valve 0 030 0 062 0 12 77 Cylinder inner diameter Standard mm Service limit mm 66 010 66 030 66 115 O Piston skirt outer diameter Standard mm Service limit mm 65 960 65 980 65 850 O Clearance between piston and cylinder Standard mm Service limit mm 0 030 0 070 0 120 O Side clearance of piston ring Standard mm Service limit mm 0 03 0 06 0 15 78 Piston ring end clearance Locate the piston ring into cylinder with piston top and measure the piston end clearance Standard mm Service limit mm 0 20 0 35 1 0 Piston ring height Standard mm Service limit
26. eriously injured when handling fuel Keep heat sparks and flame away Wipe up spills immediately 1 Drain the fuel from the tank and carburetor and then remove the following parts Rear cover Front cover and control panel Right Left side cover 2 Disconnect the fuel tube from the fuel tank and remove the fuel filter 3 Remove the clogged foreign material from the fuel filter and check the fuel filter for damage Replace the fuel filter if necessary 4 Remove the fuel tank and clean it with cleaning solvent and allow the fuel tank to dry thoroughly 5 After cleaning install the fuel tank and set the fuel filter in the tank Connect the fuel tube 6 Install the removed parts in the reverse order of removal 7 Fill the fuel tank with gasoline and check the fuel tube for gasoline leakage Fuel tank Fuel filter Hoop Fuel pipe 38 4 8 Fuel tube Fuel pump E Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Keep heat sparks and flame away Wipe up spills immediately 1 Drain the fuel from the tank and carburetor and then remove the following parts Rear cover Front cover and control panel Right Left side cover 2 Check the fuel tube for deterioration cracks and gasoline leakage If there is any abnormality in the fuel tube replace the tube 3 Check the diaphragm tube for deterioration crack and oil leakage If there is any abnormality in the
27. filler cap and check the oil level Maintenance cover AE np A Screw gt S Y ks k u AOL A fe El B J We j I A N oe De w y I SH er g S HA 2 I Upper Limit FR BR ay PA Lower Limit Dipstick Q 2 n Tk Sue a L h i ISHS A E Bg Oil drain hole 3 If the oil level is low add to the edge of the oil filler port E Replace the engine oil 1 Disassemble the oil dipstick and oil drain bolt drain out dirty oil 2 Fix the oil drain bolt tightly 3 Refill in clean oil Oil capacity is 0 4L X Recommended oil SAE10W 30 or SAE30 API Service Classification SE SF or SG SAG5W 30 or API Service Classification SF or SG for cold area 4 Check the oil level fill to the upper limitation level if necessary 29 5 Tighten the oil dipstick E Please dispose of the used motor oil in a manner that is compatible with the environment We suggest you take used oil in a sealed container to your local recycling center or service station for reclamation Do not throw it in the trash pour it on the ground or down a drain E Drain the used oil while the engine is warm Warm oil drains quickly and completely 4 3 Checking the low oil alarm 1 Disconnect oil alarm connector when the engine is still running connect the two plugs be sure that oil alarm lights and engine stops Orange Yellow green Orange Ignitor outlet terminal Alarm outlet terminal the two plugs
28. g pull wheel 10 2 Inspection 1 Ignition winding Measure the resistance between the green terminal and yellow green terminal Resistance 0 26 0 280 2 Outer charging winding Measure the resistance between the two blue terminals Resistance 0 12 0 150 3 Sub winding Measure the resistance between the two white terminals Resistance 0 12 0 140 4 Main winding 62 Measure the resistance among the three black terminals 120V 230 240V Resistance 0 8 1 10 3 3 3 50 5 Trigger Attach the two testers in the trigger and measure its resistance Trigger resistance 80 1300 10 3 Trigger adjustment Adjust the clearance between trigger and the projection part of rotor Trigger clearance 0 50 0 75mm Insert a feeler gauge between the trigger and the projection part of the rotor loosen the trigger fixed plate bolt to adjust the clearance slightly Never move the plastic part of trigger to avoid it separates from the fixed plate and damages the trigger 63 11 VALVE COVER ROCKER ARM ASSEMBLY 11 1 Disassembly Reassembly Cylinder cover Gasket of respirator partition plate Reassembly Check gasket for damage before installation Respirator partition plate Adjusting nut of valve clearance Adjusting screw of valve clearance Rocker arm shaft Rocker arm of exhaust valve 11 2 Inspection Rocker arm
29. han specified in the Maintenance Schedule E Never run the engine with a damaged or missing air cleaner 32 4 5 Spark plug Inspection Cleaning 1 Remove the spark plug cap and remove the spark plug 2 Remove carbon or other deposits with a plug cleaner or stiff ire brush Check the sealing washer for damage 3 Measure the plug resistance replace the spark plug if the measure is not accord with the asked valve Spark plug resistance 3 9K Q Gp LHJ 4 Measure the plug gap with a wire type feeler gauge Adjust by bending the side electrode if the outside the specification Spark plug clearance 0 6 0 7mm Standard spark plug A7RTC 33 E sm ae 5 Install the plug finger tight to seat the washer and then tighten with a plug wrench Torque valve is 25 30 N m 34 4 6 Valve clearance Caution E Valve clearance inspection and adjustment must be performed with the engine cold 1 Remove the following parts Front cover control panel Rear cover Right left side covers Fuel tank Inverter unit Recoil starter fan cover Inlet Exhaust side baffle 2 Remove the four tighten bolts and disassemble the cylinder cover Don t remove the cylinder cover with excessive force It can deform the cylinder cover Replace the cylinder cover if it is deformed t SY 8 Cylinder head cover Respirator clapboard gasket
30. he resistance by connecting one testing pen with the metal outer case of engine and the other testing pen with the 10P connector Standard resistance Primary coil of the ignition coil 0 8 1 30 There should be no continuity with correct Orange Oil level alarm llievel Trigger coil 80 1300 Yellow Green Continuity Ignitor unit power coil winding 0 26 0 280 i There should be no continuity with the Engine switch i switch ON continuity with the switch OFF Blue Ora nge eHow low reen Red Green Oil switch 50 Engine switch Check the continuity of connector there should be continuity if presses down the micro switch otherwise Disconnect the switch Press down eRectifier Measure the on or off positive pressure fall of rectifier with control potentiometer Pt gt the measurement should accord with the standard as shown in the chart 1 Negative pin 2 AC pin 4 AC pin 3 Positive pin 51 8 Housing case Fuel tank Guide Plate Bottom Plate Inverter unit 8 1 Disassembly and reassembly of housing case Right housing case Top cove Fuel tank cover ea Fuel tank port gasket Right housing case cross protection frame yP a 4 Inverter unit Es LM Coss protection frame shock pad Cs Protection sleeve 3 7 Plug in Fixed seat of pulling handle eLeft Housing Case o Fuel pump Oil switch handle Oil switch Smart switch Smart sw
31. hole completely pass it through the handle and make a 8 knot then turn off handle cover Loosen the reel to rebound the spring take care not to allow the reel pop out 5 Install the starter pallet and fix it with bolts 59 Pallet Spring cap Pallet guide plate Smear the lubrication grease a the back side Tighten bolt Smear screw stop solvent Pallet spring Friction spring 6 Pull the starter for several times and check the ratchet wheel returning 60 9 3 Ignition Coil Inspection O Attach the two leads of tester to the primary coil plug of ignition coil and measure the primary resistance of the ignition coil Primary resistance 0 8 1 30 O Attach one lead of the tester to each terminal of primary coil plugs of ignition coil and the other lead to the spark plug cap then measure the secondary resistance of the ignition coil Secondary resistance 15 21kQ 61 10 Alternator Trigger 10 1 Alternator Disassembly Reassembly Semicirclular key Installation check the installation don t miss anything Motor rotor Mounted panel of trigger Installation remove oil and dirty from the Pulse coil tapered part before installation Trigger Flywheel nut M14X1 5 80 90 N m Impeller Location pin re Motor stator 2 Motor sealing coil Impeller pressure plate Startin
32. in Ss Location plastic I Wheel shaft support Handle key press Handle cover Gasket 55 9 Recoil starter Air conduct cover Ignition coil 9 1 Disassembly Reassembly Seal sheath Ignition coil Recoil starter Air conduct cover 56 Starting pull rope Installation check the starting pull rope for crack and damage before installation Starting handle cover Recoil starter spring Disassembly Put on glove to operator and take care not to allow the recoil spring to pop out Installation Hang the outer hook into the reel groove and the inner hook on the jackcatch of outer shell Starting handle Starter outer shell Starter reel Installation Install the starter spring onto reel then install reel on the starter outer shell Friction spring Pallet guide plate Spring cap Pallet spring Pallet 57 9 2 Installation of recoil starter 1 Set the spring into the starter reel and hang the spring outer hook inside the reel groove Starter reel 2 Smear lubrication grease on the starter outer shell claw install the starter reel Revolve the reel anticlockwise to hang the spring inner hook on the starter outer shell claw Starter reel Starter outer shell 3 Make a 8 knot at one end of the rope pass the other end through the reel hole Wind the reel anticlockwise 4 turns to fix the reel 58 4 Pull out rope thrum from starter outer shell
33. itch baffle ys 52 cl Left housing case f f Y Fuel pipe Fuel pump Diaphragm pipe Fuel pipe Fuel tank Oil switch Fuel pipe Clip hoop 8 2 Fuel Tank Caution Gasoline is highly flammable and explosive You can be burned or seriously injured when handing fuel Keep heat sparks and flame away Wipe up spills immediately Loosen the drain screw to drain the carburetor thoroughly before removal ttt Af J ne N 1 Groove is blocked at flange E Fuel tank Capacity 4 61 t Installation N Clean the dirty and water at the bottom before installation Left housing case cross protection frame _ Oil scale Filter cup Ventilation valve O ring Fuel tank port gasket 5 ce Ff Seal ring of fuel tank cover Fuel tank cover Ventilation filter E Inner cup gt Spring Washer A T Lock pin 3 Z Right housing case cross protection frame The left and right assembly can t be mixed Strainer Hoop Fuel pipe 53 8 3 Guide Plate Bottom Plate Exhaust pipe gasket Exhaust side guide plate Inlet side guide plate x Low air conduct guide plate Plug in I 54 8 4 Bottom Plate for IG2600h Location plastic oca lt Spring Il n plastic Location pin z Connection rod Pulling tube i I tube assembl Supporting tube PA Steel ball Pulling tube assemble Wheel cover Wheel P
34. itfy bridge 3 a 2 I gt I o 3 Black 1e gt 2 Yellow Green 11 1 6 IG2600P mek z Red 3 White Black 5 6 Inverter Overload Blue DC Receptacle Rectifier D Black Winding Stop Switch Low Dil Switch lenition Spark Plug Ignition Coil Yellow Green 12 2 Service information 2 1 The importance of proper servicing E Proper servicing is essential to the safety of the operator and the reliability of the engine Any error or oversight made by the technician while servicing can easily result in faulty operation damage to the engine or injury to the operator A Warning E Improper servicing can cause an unsafe condition that can lead to serious injury or death Follow the procedures and precautions in this shop manual carefully E Some of the most important precautions are given below However we cannot warn you of every conceivable hazard that can arise in performing maintenance or repairs Only you can decide whether you should perform a given task A warning E Failure to follow maintenance instructions and precautions can cause you to be seriously hurt or killed Follow the procedures and precautions in this shop manual carefully 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 main
35. just trigger clearance Abnormal Check the ignition coil resistance and high pressure cable high pressure insulation cap Normal Inspection or replace wire harness Replace the ignition coil 21 3 3 Engine oil level is low but engine does not stop Defective oil alarm device Drain out oil completely disconnect alarm No continuity connection wire and check the continuity between alarm outlet terminal and ground Replace the oil level alarm Continuity plug and check the continuity between the plug orange wire and ground Continuity Igniter fault replace the igniter 3 4 Engine stops running Throttle is at the correct position Oil alarm Check the oil level and oil alarm Fill oil and restart the engine Sufficient oil Reset the alarm connection wire disconnect No fuel igniter plug and check the continuity Fill in fuel and restart the engine between the plug orange wire and ground Blocked Clear the fuel switch and fuel ilter Sufficient fuel Check the fuel switch and fuel filter fo blockage no blocked Check the fuel supply pipe for blockage SR Hed or replace the fuel supply No blocked Check the fuel switch and fuel filter fo Blocked i blockage Disassemble and clear so blocked Check sealing of inlet gasket and carburetork Abnormal ighten nut or replace the heat insulation block gasket Normal 1 Check the valve clearance Chec
36. k the carbon deposit in Measure the cylinder compression ABNORMA combustion chamber 3 Check the piston piston ring Normal and cylinder for damage Abnormal Check the trigger clearance Readjust the trigger clearance Normal Perform the throttle control system test 22 3 5 Engine speed can t increase or unstable choke is at the correct position Blocked Check the air filter element for blockage Clear the air filter element No blocked Check the valve clearance Abnormal Readjust the valve clearance Normal Remove the spark plug and check the Abnormal Clear electrode adjust clearance electrode clearance for carbon deposit or replace the spark plug Normal Blocked nozzle fo and the carburetor Clean or replace Tighten the nut and or replace the gasket or heat insulation block No blockage Check sealing of inlet line gasket and Abnormal carburetor heat insulation block Normal 1 Check the valve clearance M th lind Abnormal P Check the carbon deposit in easure the cylinder compression o mbustiohchamber 3 Check the piston piston ring Normal and cylinder for damage Perform the throttle control system test 3 6 Throttle control system test Bear 1 Engine speed too high or too low Abnormal _ Perform the generato Check the AC output roubleshooting following the instruction of No or low AC output Normal Abnormal
37. lack Model Sub winding color White White Item 120V 240V Voltage between gt 30V gt 60V phase wires Sub winding 4V voltage Phase sequence arrangement Green E phase Red C phase Rec C prase een B phe Black nutural Ine Yellow A phase 120V 240V Main winding Black White Sub winding 25 3 9 No DC output Is th d 12 Abnormal Perform the throttle control system s the engine speed normal test Normal Abnormal Check the DC output Replace the DC receptacle Normal Abnormal Check the DC output Replace the rectifier Normal Measure the resistance between the Abnormal Check the wire harness or replace blue terminals of the rectifier the stator Resistance 0 12 0 150 Normal Rotor losses magnetism and replace the rotor later models have a fuse in the receptacle Check the fuse before replacing the receptacle 3 10 No Parallel Output prior to 2011 model year E Make sure that the parallel output cables are inserted into the parallel cable connectors on the control panel A warning i E Use only KIPOR parallel output cables E Use only the KIPOR parallel output box E Don t use any control panel receptacles when running in parallel E Don t disconnect the parallel cables while either generator is operating Check whether the two generators could Abnormal Perform single generato ork well separately roubleshooting Normal Is se of the over load indi
38. outer diameter Standard mm Service limit mm 5 972 5 980 5 91 64 Rocker arm inner diameter of inlet exhaust valve Standard mm Service limit mm 6 000 6 012 6 05 e O Inner diameter of rocker arm bearing Standard mm Service limit mm 6 000 6 012 6 05 65 12 Crankcase Cover Camshaft Timing Driving Chain 12 1 Disassembly Spark plug Chain pressure plate Cam timing drive chain wheel Roller chain Drive shaft a Crankcase cover gt a ir Location pin of z crankcase cover Clip block Spring pin shaft n Pi Support plate of chain 66 12 2 Crankcase cover Oil dipstick Oilgear shaft Crankcase cover Ollgear Retainer ring 12 3 Reassembly of roller chain 1 Install the crankshaft piston and connection rod assembly on the cylinder block 2 Revolve the crankshaft align the timing mark of crankshaft timing shaft with the timing mark of crankcase Step 1 3 Install the roller chain on the cam timing drive chain level the timing mark upward Step 2 4 Put the roller chain into the crankcase set the end of roller chain to the crankshaft timing gear Step 3 straighten the chain to align the timing mark of cam timing drive chain with cylinder head sealing face Caution Don t remove the timing mark of crankshaft timing gear during installation If the timing mark of cam timing driv
39. tenance 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 Be careful for carbon monoxide poisoning from engine exhaust Be sure there is adequate ventilation whenever you run the engine Be careful for burns from hot parts Let the engine cool before you touch it Be careful for injury from moving parts E Do not run the engine unless the instruction tells you to do so Even then keep your hands fingers and clothing away E To reduce the possibility of a fire or explosion be sure when working around gasoline use only a nonflammable solvent not gasoline to clean parts Keep all cigarettes sparks and flames away from all fuel related parts 13 2 3 Service rules 1 Use genuine KIPOR or KIPOR recommended parts and lubricants or their equivalents Parts that do not meet Kipor s design specifications may damage the engine 2 Use the special tools designed for the product 3 Install new gaskets O rings etc when reassembling 4 When torquing bolts or nuts begin with larger diameter or inner bolts first and tighten to the specified torque diagonally unless a particular sequence is specified 5 Clean parts in cleaning solvent upon disassembly Lubricate any sliding surfaces before
40. tor under average condition 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 eAC External characteristic curves gt O O y 230 z C lt 0 5 220 O m V CURRENT A 0 2 4 6 8 12 gt O O c y 240 lt 9 If 230 O m V CURRENT A 0 2 4 6 8 12 gt O O I 120 lt O e 110 O m V CURRENT A 0 4 8 a 16 20 eDC External characteristic curves 26 24 22 20 18 16 14 12 A IJOVLIOALNILNO 9d CURRENT A 0 2 1 4 DIMENSIONAL DRAWING UNIT mm a IG2600 b 162600h 10 1 5 WIRING DIAGRAM 162600 Black Green Red Black m Green S Main winding Black Black y White o Sub winding f Inverter cell 9 White Brown 9 Yellow mu Gray B Yellow Green o l o 0 Blue Red _ N Oo 3 Pink l Black i l White Ze iis Orange Working indicator Gray g Blue Blue fe Red T reen m Green A Blue en Yellow Grgen Yellow Green Overload indicator Blue Yellow __ Yellow g S i a Orange faz 3 5 Blue Low oil indicator R 2 S Os 0 8 R lt S lt z S 8 2 a S Stoa 123 9 Rec
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