Kipor KG390 Service Manual
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Kipor KG390 Service Manual

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KG390 Engine Service Manual
The Coast Distribution System,
Ver. 2, October 1, 2007

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Summary of Contents for Kipor KG390

  • Page 1 KG390 Engine Service Manual The Coast Distribution System, Ver. 2, October 1, 2007...
  • Page 2 Preface This manual covers the specifications, construction, and overhaul of the KG390 engine used on the Coast Distribution System KGE5500E generator. Maintenance procedures as well as details on external engine parts are found in the IG6000 generator service manual. This current model is significantly changed from the engine used in the KGE6500X/E and models currently sold outside North America.

  • Page 3: Table Of Contents

    CONTENTS 1. Specifications............................1 2. Service..............................2 2.1 The Importance of Proper Service.......................2 2.2 Safety Precautions..........................2 2.3 Service Rules............................3 2.4 Electrical Precautions..........................3 2.5 Serial Number and Bar Code Location....................4 2.6 Maintenance Standards........................5 2.7 Fastening Torques..........................6 3. Cylinder Cover and Cylinder Head Assembly..................7 3.1 Cylinder Head Removal........................7 3.2 Cylinder Head Disassembly and Assembly..................7 3.3 Inspection ............................8...

  • Page 4: Specifications

    1．SPECIFICATIONS Model KG390GETi Type 4-stroke,OHV, single cylinder Displacement Bore x stroke 88×64 Maximum horsepower 7.7 @ 3600 RPM Compression ratio 8.5:1 Cooling system Forced air Ignition system Transistorized electric ignition Ignition timing 28°B.T.D.C Spark plug F7RTC Carburetor Float type, Horizontal, butterfly valve type Air cleaner Dry Replaceable Element Governor...

  • Page 5: Service

    2. SERVICE AND MAINTENANCE 2.1 The importance of proper servicing Proper servicing is essential to the safety of the operator and the reliability of the 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.

  • Page 6: Service Rules

    2.3 Service Rules • 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 and void the warranty. • Use special tools designed for the product when specified.

  • Page 7: Serial Number And Bar Code Location

    • 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. • If 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.

  • Page 8: Maintenance Standards

    2.6 Maintenance standards Part Item Standard in. (mm） Service limit Maximum speed without load 3780rpm Engine Compression 0.55MPa/600rpm Cylinder block Sleeve I.D 88.015~88.035 88.17 Skirt O.D 87.96~87.98 87.85 Piston Pin bore I.D 20.002~20.008 20.05 Piston pin 19.994~20.000 19.95 Height 1.97~1.99 1.87 side clearance 0.02~0.06...

  • Page 9: Fastening Torques

    2.7 Fastening Torques Tightening torque Item Specification Kgf.m Connecting rod bolt 20~22 2.0~2.2 Cylinder cover bolt M10×1.25×80 42~46 4.2~4.6 Spark plug M14×1.25×19 25~30 2.5~3.0 Crankcase side cover M8×30 20~23 2.0~2.3 bolt Rotor nut M18×1.5 120~130 12.0~13.0 Rocker arm shaft bolt M8×16 20~23 2.0~2.3...

  • Page 10: Cylinder Cover And Cylinder Head Assembly

    3．CYLINDER COVER AND CYLINDER HEAD ASSEMBLY 3.1 Cylinder Head Removal 3.2 Cylinder Head Disassembly and Reassembly...

  • Page 11: Inspection

    3.3 Inspection 3.3.1 Free length of valve spring Standard （mm） Service limit (mm) 37.5 3.3.2 Width of valve base Standard （mm） Service limit (mm) 0.8~1.2 3.3.3 Cylinder cover Remove all accumulated carbon from the combustion surfaces. Check for cracks in the spark plug hole, valve base and valve conduct pipe.

  • Page 12: External Diameter Of Valve Stem

    3.3.4 External diameter of valve stem Standard （mm） Service limit (mm) intake 6.570~6.585 6.50 exhaust 6.55~6.57 6.50 3.3.5 Inner diameter of valve bore Standard （mm） Service limit (mm) intake/exhaust 6.600~6.622 6.68 3.3.6 Clearance between valve bore and valve conduct pipe Standard （mm）...

  • Page 13: Valve Clearance Adjustment

    3.3.7 Valve clearance adjustment Caution ● Valve clearance inspection and adjustment must be performed on a cold engine. （1）Remove spark plug, cylinder cover bolt, cylinder cover and cylinder cover gasket. Spark plug Cylinder cover Cylinder cover gasket （2）Rotate the engine in a clockwise position until the piston is at top dead center and the intake and exhaust valves are closed.
  • Page 14 （4）If adjustment is necessary, proceed as follows A. secure the rocker arm adjustment screw and loosens the nut. B. adjust the screw until the desired valve clearance is attained. C. tighten the nut. D. recheck the clearance.

  • Page 15: Crankshaft Cover, Piston And Connecting Rod, Crankshaft And Camshaft

    4 ． CRANKSHAFT COVER, PISTON CONNECTING ROD, CRANKSHAFT AND CAMSHAFT 4.1 Crankshaft Cover 4.2 Crankshaft, camshaft and piston M8 20-22N.m...

  • Page 16: Alignment Of Timing Marks

    4.3 Alignment of timing marks Use marks to align camshaft gear and timing gear during installation. 4.4 Bearing clearance Clean and dry the shaft, rotate the shaft manually and check the free gap; replace the shaft if any noise or movement. 游...

  • Page 17: Piston And Connecting Rod

    4.5 Piston Ring and Connecting Rod Manufacture mark...

  • Page 18: Piston Ring Assembly

    4.6 Piston Ring Assembly ● put the manufacturers mark facing up during installation ● be careful not to mix the first and second rings ● check that the piston rings can rotate freely when installed. ● align the piston ring gaps at a 120 degree angle. 第一道环（...
  • Page 19 4.7.2 External diameter of the apron of piston Standard （mm） Service limit (mm) 87.96~87.98 87.85 10m m 4.7.3 Clearance between piston and cylinder Standard （mm） Service limit (mm) 0.045~0.065 0.120 ● Side clearance of piston Standard （mm） Service limit (mm) 0.020~0.060 0.150...
  • Page 20 4.7.4 Terminal clearance of piston ring Fix the piston ring in the cylinder using the top part of piston and measure the terminal clearance of piston. Standard （mm） Service limit (mm) 0.20~0.35 4.7.5 Piston ring height Standard （mm） Service limit (mm) ring/2 ring 1.97~1.99...
  • Page 21 4.7.6 External diameter of piston pin Standard （mm） Service limit (mm) 19.994~20.000 19.950 4.7.7 Internal diameter of piston pin bore Standard （mm） Service limit (mm) 20.002~20.008 20.050...

  • Page 22: Connection Rod Inspection

    4.7.8 Clearance between piston pin and piston pin bore Standard （mm） Service limit (mm) 0.002~0.014 0.080 4.8 Connecting Rod Inspection 4.8.1 Internal diameter of connecting rod small end Standard （mm） Service limit (mm) 20.007~20.020 20.090 4.8.2 Internal diameter of the connecting rod big end Standard （mm）...

  • Page 23: Crankshaft Inspection

    4.9 Crankshaft Inspection 4.9.1 External diameter of main journal Standard （mm） Service limit (mm) 35.960~35.975 35.900 4.9.2 Clearance of connecting rod big end and crank journal Standard （mm） Service limit (mm) 1.05~1.25...
  • Page 24 4.9.3 Clearance of crankshaft oil film and connecting rod big end （1）Remove the engine oil on the surface of journal. （2）Set plastic line gauge on the journal and install the connecting rod. Tighten the connecting rod bolts to the specified torque (14-16 Nm.). Do not rotate the crankshaft when tightening. （3）Remove the connecting rod and measure the thickness of plastic line gauge.

  • Page 25: Camshaft Inspection

    4.10 Camshaft Inspection 4.10.1 Height of camshaft Standard （mm） Service limit (mm) Air intake 32.60~32.80 32.25 Air outlet 32.09~32.29 31.75 4.10.2 External diameter of camshaft Standard （mm） Service limit (mm) 15.95~15.99 15.92...
  • Page 26 4.10.3 Inner diameter of camshaft bearing Standard （mm） Service limit (mm) 16.000~16.018 16.050...

  • Page 27: Electric Starter

    5. ELECTRIC STARTER...

  • Page 28: Disassembly And Reassembly

    5.1 Disassembly and Reassembly 5.1 Disassembly of meshing gear assembly (with clutch) Lift the shaft so the meshing gear faces upward. Place a hex wrench at the bottom of thrust washer and rap gently with hammer. Remove the snap ring then remove the washer from shaft. Thrust washer Meshing gear assembly (with clutch) 5.2 Inspection...
  • Page 29 Caution: Heavy current will be generated when connecting draw coil, perform measurement quickly to avoid any damage caused by over hot coil. 5.2.2 Brush length Measure the brush length, repair or replace the brush if the wear exceeds maintenance limit. Standard value Service limit 15mm...
  • Page 30 5.2.4 Conductivity between sector parts Check the conductivity between sector parts; if any un-conductivity, replace the armature. 5.2.5 Insulation between commutator and shaft Check the continuity between the commutator and shaft. Replace the armature if there is any continuity. 5.2.6 Meshing gear assembly (with clutch) - Meshing gear inspection Check for any wearing or damage of the driving gear teeth.
  • Page 31 5.2.7 Spline gear inspection Check if the driving gear moves freely on the rotor shaft and check for wear. Replace as necessary. 检查 部位 Inspection section 5.2.8 Brush holder inspection Check movement of the brushes in the holder. If any resistance is noted, check for distortion or dirt on the sliding surface.
  • Page 32 - Inspection of excitation coil ground Check the continuity between the brush and starter cover. Any continuity means the coil has failed.

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