Kipor IG6000 Service Manual
  1. Manuals
  2. Brands
  3. Kipor Manuals
  4. Inverter
  5. IG6000
  6. Service manual

Kipor IG6000 Service Manual

Hide thumbs Also See for IG6000:
Table of Contents

Advertisement

Quick Links

IG6000
IG6000h
Generator Service Manual
Kipor Power Systems August 1, 2011

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the IG6000 and is the answer not in the manual?

Questions and answers

Related Manuals for Kipor IG6000

Summary of Contents for Kipor IG6000

  • Page 1 IG6000 IG6000h Generator Service Manual Kipor Power Systems August 1, 2011...
  • Page 2 Preface This manual covers the construction, function and servicing procedure of the KIPOR KGE7000Ti single voltage generator and the dual voltage KGE6000Ti and IG6000 generator. This manual covers generator specifications, function, troubleshooting and repair. Careful observance of the instructions contained in this manual will result in safe and quality service work.

  • Page 3: Table Of Contents

    6. Control Panel, charging adjustor, timing relay, Ignition control module, inverter Module..... 6.1 Disassembly and Reassembly..................... 6.2 Inspection..........................7. Housing group and Fuel Tank......................7.1 Disassembly and Reassembly (IG6000)..................7.2 Disassembly and Reassembly(IG6000h)..................7.3 Vaporize control system……………………………………………… ………………….. 8. Alternator, Ignition Coil, Trigger, electric motor, air guide cover............

  • Page 4: General Specifications

    1．SPECIFICATIONS and DIAGRAMS 1.1 General Specifications Dimensions and weights Model IG6000 Overall length- in. (mm) 31.6 (802) Overall width- in. (mm) 19.4 (498) Overall height- in. (mm) 24.6 (624) Dry weight- lbs. (Kg) 213 (96.7) Engine Model KG390GETi Type 4-stroke,OHV, single cylinder Displacement- cu.in.

  • Page 5: Generator Specifications

    1.2 Generator Specifications Model IG6000 6.0 KVA Maximum output（AC） Rated output (AC) 5.5 KVA Rated frequency (HZ) Rated voltage（AC） 120/240 Maximum current (amp) 50/25 Rated current（amp） 45.8/22.9 Rated voltage（DC） Rated current（DC） Power factor Momentary Max.10% Voltage variation Average Max.1.5% rate Average time Max.

  • Page 6: Performance Curves

    1.3 PERFORMANCE CURVES The curves show performance of the generator under average conditions. Performance may vary depending upon ambient temperature, altitude and humidity. ●AC External characteristic curves ● DC External characteristic curves...

  • Page 7: Wiring Diagram

    1.5 Wiring Diagram a. Single voltage output...
  • Page 8 b. Double-voltage output...

  • Page 9: Service And Maintenance

    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 10: 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 11: Serial Number And Bar Code 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 12 2.5 Maintenance standards of engine Part Item Standard in. (mm) Service limit ≤3780rpm Engine Max. speed under zero load (rpm) 0.55MPa/600rpm Cylinder pressure 88.015~88.035 88.17 Cylinder Cylinder sleeve I.D. Piston Piston skirt O.D 87.96~87.98 87.85 Pin bore I.D. 20.002~20.008 20.05 19.994~20.000 19.95 Piston pin...

  • Page 13: Fastening Torques

    Alternator Maintenance Standards Standard（Ω） Service Part Item Type 120V/240V 120V 240V limit Double-voltage Single voltage Orange－ 0.22~0.24 Yellow/Green Ignition winding l Resistance Gray－orange 0.15~0.17 External Resistance Blue－blue 0.03~0.04 charging winding Built-in charging Resistance Purple－Purple 0.12~0.16 winding White－white Sub winding Resistance 0.08~0.12 (green－green) Black－black...

  • Page 14: Troubleshooting

    This section gives very general information regarding symptoms and possible causes. Refer to subsequent sections regarding testing and removal and replacement of specific components and systems. Engine overhaul is addressed in the IG6000 Engine shop manual. a. General symptoms and possible causes...
  • Page 15 the electrode on the cylinder head.; start or weak the engine and check the spark conditions spark ↓normal Install a compression gauge in the spark 1. Check valve clearance; plug hole and restart the engine and 2. check cylinder head gasket for leakage. check the cylinder compression.
  • Page 16 Measure the spark plug gap and perform the spark test. Standard gap: .028-.034 in. (0.7-0.8 mm) ↓no spark Perform the spark test again using a new →normal Replace the spark plug spark plug spark ↓no spark Perform the spark test again using a new →normal Replace Ignitor ignitor...
  • Page 17 ↓normal Check each carburetor hole and main Disassemble and clean →clogged nozzle for blockage ↓not clogged Check the air intake paper gasket and Tighten the nuts securely, replace the the sealing of heat-insulation block of →abnormal gasket or heat-insulation block carburetor ↓normal Test the cylinder compression...
  • Page 18 ↓normal Check the trigger air gap →abnormal Readjust the clearance ↓normal Perform throttle control system troubleshooting g. Throttle control system troubleshooting 1). Engine speed is too high or too low Perform the generator troubleshooting Check AC output abnormal flowing the instruction of “No or Low AC output”...
  • Page 19 Disconnect the two 6P input connectors 1. Check the wiring of the stator leads in on the inverter unit. (6p for single the harness. Repair or replace the voltage , 4p or 2p for double voltage) harness. Disconnect spark plug cap or igniter 2.
  • Page 20 k. The battery doesn’t charge. Check ignition switch →abnormal Replace ignition switch ↓normal Check charging regulator →abnormal Replace the charging regulator ↓normal Measure resistance of charging coil Check and repair electric wire harness or winding →abnormal replace stator. Resistance: 0.12~0.16Ω: ↓...

  • Page 21: Inspection And Adjustment

    ② When it is used in dusty place, filter should be cleaned every 10 hours or everyday. ③ Maintenance should be carried out by the qualified technicians. PLEASE READ KIPOR OPERATION MANUAL. 3.2 Engine oil ● Checking the oil level Stop the engine and check the oil level, be sure to put the engine on a flat floor when checking.

  • Page 22: Low Oil Alarm

    ● Engine oil change （1）Remove dipstick and oil drain bolt and drain out the used oil. （2）Tighten the oil drain bolt securely. （3）Pour the specified amount of fresh engine oil through the oil filler port.（Engine oil capacity : 1.2 qt (1.1L) ※...

  • Page 23: Air Cleaner

    (2) Stop the engine and disconnect the orange wire of the low oil alarm 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.
  • Page 24 （4）Install the air cleaner element in the air cleaner case, close cabinet door. Attention ! ■Dirty air filter will affect the air into the carburetor, and reduce the engine work power. If the engine works in dirty place, please replace the air filter often. ■Don’t operate the generator without the filter element in place or serious engine damage may result.

  • Page 25: Spark Plug

    3.6 Valve clearance adjustment Attention ! Valve adjustment should only be performed on a cool engine. （1）Remove spark plug, valve cover bolt, valve cover and valve cover gasket. Spark plug Valve cover gasket Valve cover （2）Insert a feeler gauge in the spark plug installation hole; Rotate the engine so the piston is at top dead center and both intake and exhaust valves are closed.

  • Page 26: Fuel Switch/Fuel Filter

    3.7 Fuel switch and fuel filter cleaning Fuel tank Sealing gasket Filter core or element Fuel switch Attention ! ■ Keep smoking materials and any open flames away during fuel system maintenance. ■ Make sure that there is no leaking fuel after service. （1）Drain the fuel from the tank then remove the fuel tank.

  • Page 27: Air Cleaner

    4．AIR CLEANER and MUFFLER 4.1 Air cleaner ● Disassemble and reassemble Bottom case of air filter Sealed gasket Filter fixed price Filter element Carburetor gasket Air filter cover Install: Make sure that gaskets have no damage or deformation. Check sealing surfaces on all four sides 4.2 Muffler ●...
  • Page 28 4.3 Air outlet pipe, second gulp valve assembly Secondary air injection valve 二次补气阀组件 Bolt 螺栓 Spark Arrestor 防火帽组件 Muffler body assembly 消声器本体总成 Gasket A 垫片A 排气管 Muffler elbow pipe...

  • Page 29: Disassembly And Reassembly

    5．CARBURETOR WARNING ■ 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 Disassembly and reassembly Carburetor gasket A Reassembly: Check if there is any damage in the gasket before assembly ●...
  • Page 30 Carburetor disassembly and reassembly...
  • Page 31 5.2 Stepping motor/ fuel shutoff solenoid ●Floater height Place the carburetor as fig. and measure the size between floater and body.(floater height) Specified height 14mm If the floater height don’t meet the specified height, please replace. ●Stepping motor 1）Measure the resistance of outlet terminals of stepping motor 1 and 3：50~55Ω...

  • Page 32: Inspection

    6. CONTROL PANEL, CHARGING ADJUSTOR, TIMING RELAY, IGNITION CONTROL MODULE and INVERTER UNIT 6.1 Disassembly and assembly Control panel Timing relay Ignition control module Module fixing plate 2 Inverter unit Charging regulator Module fixing plate1 6.2 Inspection a. Control panel AC Receptacle Check for evidence of burning or contact damage.
  • Page 33 Color of wire Circuit unit Stipulated resistance Blue Primary coil of the ignition coil 0.8~1.3Ω Orange Low oil alarm No continuity under normal oil level Yellow Coil of trigger head 80~130Ω Yellow/Green ground Continuity Green Power coil winding of module 0.37~0.41Ω...
  • Page 34 Continuity Continuity Continuity Infinity Infinity Continuity (1)Negative terminal (-) (2) AC terminal (~) (3) AC terminal (~) (4)Negative terminal (+) b. Charging Regulator Loosen the positive battery cable when starting the engine and connect a DC current meter between the positive cable and positive terminal.
  • Page 35 Yellow Green White Blue Black Black d. Ignition Control Relay Start the engine, turn off the smart throttle and measure the voltage between green and yellow/green wires on the connection of the control module. Replace the ignition control module if the voltage exceeds stipulated voltage.
  • Page 36 7. FRAME, HOUSING and FUEL TANK 7.1 Disassembly and reassembly（IG6000）...
  • Page 37 7.2 IG6000h handle assembly 7.3 Vaporize control system...
  • Page 38 ALTERNATOR, IGNITION COIL, TRIGGER, FAN COVER 8.1 Component Identification a. Disassembly and assembly...

  • Page 39: Inspection

    8.2 Ignition coil and trigger a. Disassembly and reassembly 触发头 Trigger 点火线圈 Ignition 点火线圈支架 Bracket for ignition coil coil b. Inspection (1) Ignition coil ● Insert each meter pen between the primary coil plug-in of ignition coil to measure primary resistance of ignition coil.
  • Page 40 (2) Trigger ● Insert each meter pen to each trigger outgoing line to measure trigger resistance. Trigger head 80~130Ω resistance C. Adjustment Adjust the clearance between the trigger head and rotor. Trigger head .020-.029 in. (0.50~0.75 mm) clearance Insert the feeler gauge between the bulge on the trigger head and the rotor to measure clearance. Loosen the two bolts on the bracket to obtain the proper.

  • Page 41: Alternator

    8.3 Alternator a. Disassembly and reassembly Flywheel nut M8x1.5 120-130N m) b. Inspection (1) Ignition coil Orange-Yellow/green 0.22~0.24Ω Resistance value Gray-Orange 0.15~0.17Ω (2) External charging coil Measure the resistance between the two blue wires Resistance value 0.03~0.04Ω (3) Built-in charging coil Measure the resistance between the two purple wires.

  • Page 42: Cylinder Cover, Valve

    9. CYLINDER COVER and VALVE 9.1 Disassembly and reassembly...

  • Page 43: Inspection

    9.2 Inspection ● Valve spring length Standard(mm) Service limit(mm) 37.5 ●Valve seat width Standard(mm) Service limit(mm) 0.8-1.2 ●Cylinder cover Remove all accumulated carbon in burning room and the washer remains on cylinder cover, and then check for crack of spark plug holes, valve base and valve conduct pipe. Check for distortion of cylinder cover with ruler and feeler gauge.
  • Page 44 ●Inner diameter of valve guiding pipe Standard （mm） Service limit (mm) Air intake/outlet 6.600-6.622 6.68 ●Clearance between valve rod and valve guiding pipe Service limit (mm) Standard （mm） Air intake 0.015~0.052 0.11 Air outlet 0.030~0.072 0.13...

  • Page 45: Disassembly And Reassembly

    10. CRANKCASE COVER, CAMSHAFT, PISTON and CONNECTING ROD 10.1 Disassembly and reassembly a. Crankcase cover b. Crankshaft, camshaft and piston...
  • Page 46 ●Alignment of time setting marks Align camshaft with comparison marks of time setting gear (small gear on camshaft) before installing. c. Piston and connecting rod...

  • Page 47: Inspection

    Assemble of piston ring Caution ● Put the manufacturer mark facing up when installation; ● Pay attention to the installation positions of 1 and 2 ring. ● Check if the piston ring can rotate freely after installing. ● All openings of piston ring should be kept away from the direction of piston pin with 120 degree angle. 10.2 Inspection Inspection of low oil alarm (1）Lift the low oil alarm and measure the conductivity between lead wire and copper grounding piece...
  • Page 48 ● Inner diameter of cylinder Standard （mm） Service limit (mm) 88.015~88.035 88.17 ● External diameter of the apron of piston Standard （mm） Service limit (mm) 87.96-87.98 87.85 10mm ● Clearance between piston and cylinder Standard （mm） Service limit (mm) 0.045~0.065 0.120 ●...
  • Page 49 ● Terminal clearance of piston ring Fix the piston ring in cylinder using the top part of piston and measure the terminal clearance of piston. Standard （mm） Service limit (mm) 0.20~0.35 ● Height of piston ring Standard （mm） Service limit (mm) The first ring/the 1.97~1.99 1.87...
  • Page 50 ● Internal diameter of piston pin hole Standard （mm） Service limit (mm) 20.002~20.008 20.050 ● Clearance between piston pin and pin hole Standard （mm） Service limit (mm) 0.002~0.014 0.080 ● Internal diameter of the small terminal of connecting rod Standard （mm） Service limit (mm) 20.007~20.020 20.090...
  • Page 51 ● External diameter of crankshaft journal Standard （mm） Service limit (mm) 25.960~35.975 35.900 ● Clearance of side face of big terminal of the connecting rod Standard （mm） Service limit (mm) 1.05~1.25 ●Clearance of oil film of big terminal of connecting rod （1）Remove the engine oil on the surface of crankshaft journal.
  • Page 52 ● Height of camshaft Standard （mm） Service limit (mm) Air intake 32.60~32.80 32.25 Air outlet 32.09~32.29 31.75 ●External diameter of camshaft Service limit (mm) Standard （mm） 15.966~15.98 15.92 ●Inner diameter of bearing of camshaft Service limit (mm) Standard （mm） 16.000~16.018 16.050...

This manual is also suitable for:

Ig6000h

Table of Contents