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Summary of Contents for Kipor KGE3000Ti
- Page 1 KIPOR KIPOR POWER GENERATOR SHOP MANUAL SINEMASTER DIGITAL GENERATOR KGE3000Ti...
- Page 2 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.
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Page 3: Table Of Contents
Table of Contents 1. Specifications ........................3 1.1 Specifications.........................3 1.2 Characteristics ......................4 1.3 Performance curves .....................7 2. Service information ......................8 2.1 The importance of proper service ................8 2.2 Important safety precautions ..................8 2.3 Service rules ........................9 2.4 Electrical Precautions ....................9 2.5 Serial number location....................10 2.6 Maintenance standards ....................11 2.7 Torque values ........................12 2.8 Troubleshooting ......................13... -
Page 4: Specifications
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 132 lbs, 60 kg Engine Model KG205 Type 4-stroke,overhead valve, single cylinder Displacement in (cc） 12.0 (196) Bore x stroke in.(mm) 2.68 x 2.13 (68×54) Horsepower... -
Page 5: Characteristics
PWM(Plush width modulation) Phase Three phase Rotating direction Clockwise (Viewed from the generator) Frequency regulation AC-DC-AC conversion (Inverter type) 1.2 CHARACTERISTICS Model 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... -
Page 6: Performance Curves
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. -
Page 7: Wiring Diagram
1.5 WIRING DIAGRAM DC socket Blue Blue Charging winding Blue Blue Rectifier Bridge Black Green Green Black Black Black White Black Brown Black Single phase socket Main winding Gray Olivine Inverter unit Yellow White Orange Sub winding Blue Black White White Pink Brown... -
Page 8: Service Information
2. Service information 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 9: 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. · Use the special tools designed for the product. · Always install new gaskets, O-rings, etc. when reassembling components. -
Page 10: Serial Number Location
· Clamp the wire harnesses securely so that they do not interfere with the rotating parts, moving parts and hot parts. · Route and connect the wire harnesses properly. Be sure that the harnesses are not slack, twisted or pulled overly taut. ·... -
Page 11: Maintenance Standards
2.6 Maintenance standards Engine Part Item 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 2.68~2.68 (67.97~67.99) 2.68 (67.62) Piston-to-cylinder clearance .0016~.0023 (0.040~0.060) .0047 (0.12) Pin bore I.D. 18.002~18.008 18.042 Piston pin .708~.709 (17.990~18.000) .709 (17.95) Pin-to-piston clearance .0001~.0071 (0.002~0.018) -
Page 12: Torque Values
Generator Standard（Ω） Service Part Item Type limit 120V Ignition coil Resistance Yellow/Green—Green 0.26~0.28 — 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... -
Page 13: Troubleshooting
2.8 Troubleshooting A. General symptoms and possible causes Symptom Cause(s) Remedy Carburetor float chamber contains stale Drain old fuel, clean and /or replace gasoline, or no fuel reaches carburetor Fuel tank tube clogged Inspect Fuel filter clogged Clean Carburetor failure Clean and/or replace* Engine does not Spark plug cap disconnected... - Page 14 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. No fuel Check the fuel level in the tank Add fuel and restart the engine Sufficient fuel Loosen the drain screw and Abnormal...
- Page 15 electrode. Warning Warning ■ 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.
- Page 16 D. Engine oil level is low, but engine does not stop. Drain all the oil, disconnect wire of low Disconnect oil alarm and measure linkage of Replace the low oil alarm output of low oil alarm and the ground Connect the wire of low oil alarm Disconnect and disconnet portfire connector plugs, then measure li nkage of...
- Page 17 F. Engine speed does not increase or stabilize. Clogged Check the air cleaner Clean the air cleaner Not clogged Abnormal Check the valve clearance Readjust valve gap Normal Clean electrodes and adjust the Abnormal spark plug gap or replace a new spark plug Normal Clogged...
- Page 18 H. No or Low AC output Disconnect the load, and Is the overload indicator light ON? restart the engine. Is the engine speed normal? Abnormal Engine speed: Perform the throttle control ± Smart switch ON: 3000 100rpm system troubleshooting ± Smart switch OFF:3600 100rpm Normal Abnormal...
- Page 19 J. Engine will not start Electrically Measure the voltage of Abnormal Change a new accumulator accumulator Normal Abnormal Check the ignition switch Replace the ignition switch Normal Abnormal Replace the starting relay Check the starting relay Normal Abnormal Check the starting motor Replace the starting motor Normal Check , repair or change...
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Page 20: Maintenance
3 MAINTENANCE 3.1 Maintenance schedule Regular service period① Each use First month Every Every Every year or or 10 Hrs. months months 300 Hrs. Item perform at every indicated 50Hrs. 100 Hrs. month or operating hour interval, whichever comes first ●... - Page 21 (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 upper oil limit level.
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Page 22: Air Filter Maintenance
(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. - Page 23 Attention ■ 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.
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Page 24: Adjusting Of Valve Clearance
(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). Adjusting valve clearance Attention Valve adjustment should only be performed on a cool engine. (1) Remove valve cover. Gasket of cylinder head cover cylinder head cover (2) Pull the starter rope gently and set the piston in top dead center (the scale of starting wheel should align with the sign “△”... -
Page 25: Fuel Filter And Fuel Switch Maintenance
(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. -
Page 26: Air Filter And Muffler
4. Air Filter and Muffler 4.1 Air filter ●Disassembly and assembly Bottom case of air filter Filter element Air filter cover 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... -
Page 27: Carburetor
5．Carburetor Attention ■ Loosen the gasoline drain bolts before disassembly to drain fuel in the carburetor. ■ 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 Rope of air choke... -
Page 28: Stepping Motor Disassembly And Reassembly
5.2 Stepping motor disassembly and reassembly stepping motor stepping motor base fork spring disassembly ： fork hold it tightly for fear that the spring will lose when it is disassemblied . fork spring fuel control fork lever... -
Page 29: Carburetor Disassembly And Reassembly
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. -
Page 30: Control Panel, Charging Adjustor And Inverter Unit
6. Control panel, charging adjustor and inverter unit 6.1 Disassembly and assembly Charging adjustor Control panel Inverter unit 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. - Page 31 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. O F F S T A R T D. Rectifier Use the 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.
- Page 32 7. Housing group and Fuel tank Fuel tank cover Reassembly Check if air vent is blocked before assembly Housing weldment Glass of float Housing door Handle sheath window weldment Sheath of fuel Window fixing Fuel tank Oil dipstick tank Inlet sheath capacity ：...
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Page 33: Generator, Ignition Coil And Trigger
8. Generator, ignition coil, trigger 8.1 Generator A. Disassembly and Reassembly Rotator Stator pin Reassembly ： Stator Clean the dirty and oil stain on the tape surface of rotator before installation. Nut of flywheel M14X1.5 80-90 N.m Fixing board of chuck Rope clutch Trigger Semicircle key... -
Page 34: Ignition Coil And Trigger
8.2 Ignition coil and trigger A. Disassembly and reassembly Trigger Wire holding board Ignition coil B. Inspection (1) Ignition coil ● With an ohmmeter check the resistance between the two wires going to the coil primary resistance 0.8~1.3Ω ●Check resistance between one end of primary ignition coil terminals and spark plug cap to measure sub resistance of ignition coil. - Page 35 (2) Trigger Test the resistance between the trigger wires. Resistance of trigger 80~130Ω Adjustment: Adjust the clearance between trigger and salient of the rotor. 0.020~0.030 in. clearance of trigger (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.
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