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                            IG6000
                            IG6000h

Generator Service Manual

The Coast Distribution System, June 1, 2007

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Summary of Contents for IG6000

Page 1: ...IG6000 IG6000h Generator Service Manual The Coast Distribution System June 1 2007 ...

Page 2: ...n than the original KGE7000Ti and other models currently sold outside North America Contact Kipor for current service information 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 app...

Page 3: ... Oil Level Alarm 11 2 8 5 Engine Speed Problems 11 2 8 6 Engine Stops After Starting 12 2 8 7 Throttle Control System 12 2 8 8 Low AC Output 13 2 8 9 No AC Output 13 2 8 10 Electric Starter 14 2 8 11 Battery Charging 14 3 Inspection and Adjustment 15 3 1 Maintenance Schedule 15 3 2 Engine Oil 15 3 3 Low Oil Level Switch 17 3 4 Air Cleaner 17 3 5 Spark Plug 18 3 6 Valve Clearance 19 3 7 Fuel Switch...

Page 4: ...1 Inverter Module 27 7 Frame Housing and Fuel Tank 28 7 1 Disassembly and Reassembly 28 7 2 IG600h Handle Assembly 29 8 Ignition Coil Trigger Alternator 30 8 1 Component Identification 30 8 2 Ignition Coil and Trigger 31 8 2 1 Disassembly and Reassembly 31 8 2 2 Inspection 31 8 3 Alternator 33 8 3 1 Disassembly and Reassembly 33 8 3 2 Inspection 33 ...

Page 5: ...Transistorized controlled ignition Ignition timing 28 B T D C Spark plug F7RTC Carburetor Horizontal float type Air cleaner Dry replaceable element Governor Inverter module control Lubrication system Forced splash Oil capacity qt L 1 2 1 1 Starting system Electric starter Stopping system Electric ground Fuel Automotive unleaded gasoline 87 octane Generator Model KD50 Generator type Multi pole rota...

Page 6: ...Power factor 1 0 Voltage variation rate Momentary Max 10 Average Max 1 5 Average time Max 3 seconds Voltage stability 1 Frequency variation rate Momentary Max 5 Average Max 5 Average time Max 05 second Frequency stability 0 1 Insulation resistance Min 10MΩ AC circuit protector Amps 120 240 VAC 51 7 25 8 DC circuit protector 15A Fuel tank capacity gal L 5 9 22 Operating hours at rated load 6 Noise ...

Page 7: ...URVES 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 8: ...4 1 4 Wiring Diagram ...

Page 9: ...ctices and that you are wearing appropriate clothing and safety equipment When performing maintenance or repairs be especially careful of the following Read the instructions before you begin and be sure you have the tools and skills required to perform the tasks safely Be sure that the engine is off before you begin any maintenance or repairs This will reduce the possibility of several hazards Car...

Page 10: ... 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 s...

Page 11: ...y winding with electrical insulating tape 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 and Bar Code Location The engine serial number is stamped beside the engine oil drain plug This ...

Page 12: ...0 0 09 0 10 0 9 1 1 2 7 Fastening Torques Item Specification Tightening torque Ft lb N m Connecting rod bolt M8 14 8 16 3 20 22 Cylinder cover bolt M10 1 25 80 31 0 34 0 42 46 Spark plug M14 1 25 19 18 4 22 2 25 30 Crankcase side cover bolt M8 30 14 8 17 0 20 23 Rotor nut M18 1 5 88 5 95 9 120 130 Rocker arm shaft bolt M8 16 14 8 17 0 20 23 Adjusting nut of rocker arm shaft M6 0 75 7 8 8 8 10 12 S...

Page 13: ...el alarm defective Inspect and replace Ignition coil defective Inspect and replace Valve clearance misadjusted Adjust valves Engine speed does not stabilize Carburetor faulty Clean and or replace Throttle control motor stepping motor defective Inspect and replace Inverter unit defective Inspect and replace Valve clearance misadjusted Adjust valves 2 8 2 Hard starting or no start Check the fuel lev...

Page 14: ...emove spark plug 2 Attach the removed spark plug to the plug cap 3 Ground the negative electrode of the spark plug against the cylinder head or engine block and engage the electric starter and check to see if a spark jumps across the electrode 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 spark plug normal...

Page 15: ...or replace air cleaner not clogged Check the valve clearance abnormal Adjust the valve clearance normal Remove the spark plug and check the electrodes for carbon and spark plug gap abnormal Clean the spark plug and adjust the spark plug gap or replace new spark plug normal Check for blockage of the main jet clogged Disassemble and clean or replace carburetor not clogged Check the air intake gasket...

Page 16: ...l Tighten the nuts securely replace the gasket or heat insulation block normal Measure the cylinder compression abnormal 1 Check the valve clearance 2 Check if too much carbon in burning room 3 Check the piston piston ring and cylinder for wear and damage normal Check the trigger air gap abnormal Readjust the clearance normal Perform throttle control system troubleshooting 2 8 7 Throttle control s...

Page 17: ...mal Disconnect the two 4P input connectors on the inverter unit Disconnect spark plug cap or igniter connector and measure the AC voltage of from the stator The output voltage across pins 1 2 2 3 and 1 3 should be 255 volts Check both connectors abnormal 1 Check the wiring of the stator leads in the harness Repair or replace the harness 2 Replace the alternator normal 255 volts Replace inverter un...

Page 18: ...r abnormal Replace the starting motor normal Check and repair or replace main wire harness 2 8 11 The battery will not charge or maintain a charge Check ignition switch abnormal Replace ignition switch normal Check charging regulator abnormal Replace the charging regulator normal Measure resistance of charging coil winding Resistance 0 12 0 16Ω abnormal Check and repair electric wire harness or re...

Page 19: ...e clearance Check Adjust Fuel tank and filter Clean Fuel line Check Every 2 years and replace if necessary Note Service more often in dirty dusty conditions Should be performed by trained service center personnel 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 1 Remove the oil dipstick and check the level Lower l...

Page 20: ...ice Classification SG SF Select the appropriate viscosity for the average temperature in your area SAE Viscosity Grades 4 After refilling check the oil level again 5 Tighten the dipstick drain the used oil while the engine is warm Warm oil drains quickly and completely 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 ...

Page 21: ...tion module Outlet terminal of oil alarm Ground through engine cover 3 4 Air Cleaner 1 Open the door of cabinet 2 Remove the air cleaner cover and remove the filter element 3 Check the element for excessive dirt or damage Replace as necessary Caution Excess oil will restrict air flow through the foam filter core and may smoke at the engine start Filter element Cover of ail cleaner Clean Twist to d...

Page 22: ...e carbon on the electrodes of spark plug with a wiey brush and check sealing washer for damage 3 Check the resistance value of spark plug and replace if the resistance value is not within the stated value Resistance value of spark plug 3 9KΩ 4 Measure the plug gap with a wire type feeler gauge If the gap is not compatible with the standard adjust by bending the side electrode Spark plug gap 028 03...

Page 23: ... 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 r 3 Insert a feeler gauge between the rocker arm and the valve and measure the valve clearance Valve clearance intake 0039 0001 in 0 10 0 02 mm exhaust 0059 0001 0 15 0 02 mm ...

Page 24: ... filter cleaning Fuel tank Sealing gasket Filter core or element Fuel switch 1 Drain the fuel from the tank then remove the fuel tank 2 Loosen the connection nut between fuel switch and tank and remove the filter core 3 Open the fuel switch to start cleaning and dry it with compressed air 4 Remove any clogged foreign material from the fuel filter core and check the fuel filter for damage 5 Install...

Page 25: ...ilter cover 4 2 Muffler Assembly Assembly Clean the carbon using the brush before instal ling Fireproofing cap Muffler syphon Cover of muffler Muffler Assembly Knock it to remove carbon in side by using rubber hammer before installing Exhaust pipe gasket Muffler gasket Install Make sure that gaskets have no damage or deformation Check sealing surfaces on all four sides ...

Page 26: ...intenance permitted other than cleaning is to replace the main jet for high altitude compensation 5 1 Disassembly and reassembly NOTE loosen the drain bolt at the bottom of the bowl and drain fuel from the carburetor before removal 28 Carburetor gasket A Reassembly Check if there is any damage in the gasket before assembly ...

Page 27: ...ver Fork 5 2 Stepping motor fuel shutoff solenoid 1 Measure the resistance of outlet terminals of stepping motor resistance value 1 and 3 50 55Ω 2 and 4 50 55Ω Replace the stepping motor if the resistance exceeds the standard 2 Measure the resistance of fuel shutoff valve resistance value 6 8Ω Replace the throttle electromagnetic valve if the resistance exceeds the standard value 2 1 4 3 ...

Page 28: ...rminals of the receptacle with a jumper wire and check if the receptacle is conductive with two meter leads inserted into the panel if not conductive press the Reset button on the receptacle panel and measure it again If there is still no continuity replace the DC receptacle 6 4 Smart Throttle Switch The switch is conductive when ON and not conductive when OFF 6 5 Ignition Module Remove the 10P co...

Page 29: ...tinuity when ON Blue Orange Yellow Yellow green Green Red 6 6 Ignition Switch Check for continuity of each group of contacts with the switch in the off on and start positions 6 7 Bridge Rectifier Measure the positive voltage drop of each leading feet of rectifier bridge with the diode checking function of the meter and the result should be compatible with the following standard Tester Tester 1 2 3...

Page 30: ...rrent present replace the regulator DC charging voltage 13 14V DC charging current 1 5A AC Input blue Shell grounding Output positive pole red 6 9 Timing relay Put the ignition switch on the OFF position connect a voltmeter to the white and yellow green wires Place the ignition switch in the ON position hold on for 7 seconds and then place in the OFF position A reading of 12V should be present for...

Page 31: ...e ignition control module if the voltage exceeds stipulated voltage Ignition voltage AC 27 32V Yellow Green Black Orange Grey Green Yellow Green 6 11 Inverter Module Unplug the two stator input connections to the module Start the engine and take a voltage reading at both 4P connections Readings between pins 1 2 2 3 1 3 should be 255VAC 15V 2 3 1 Alternator Input Terminals 4P connectors ...

Page 32: ...28 7 FRAME HOUSING AND FUEL TANK 7 1 Disassembly and reassembly ...

Page 33: ...29 7 2 IG6000h handle assembly Tightening screw Sliding sleeve Handle spring Handrail support Handrail support sleeve Stand bar Kickstand Gasket Lock pin Land wheel Wheel axle ...

Page 34: ...30 8 ALTERNATOR IGNITION COIL TRIGGER STARTER MOTOR FAN COVER 8 1 Component Identification ...

Page 35: ...头点火线圈点火线圈支架 8 2 2 Inspection a Ignition coil using an ohmmeter measure the primary resistance of the coil Primary resistance value 0 8 1 3Ω measure the secondary resistance of the coil Secondary resistance value 15 21KΩ Trigger Ignition coil Bracket for ignition coil ...

Page 36: ...Trigger head clearance 020 029 in 0 50 0 75 mm 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 When tightening apply equal torque to both mounting bolts to prevent cocking the trigger to one side Recheck the clearance after the adjustment has been made ...

Page 37: ...oil Measure the resistance between the two blue wires Resistance value 0 03 0 04Ω Built in charging coil Measure the resistance between the two purple wires Resistance value 0 12 0 16Ω Sub winding coil Measure the resistance between two white wires or green depending on the date of manufacture Resistance value 0 08 0 12Ω Flywheel nut M8x1 5 88 5 95 9 ft lb lob 120 130N m ...

Page 38: ...34 Main winding Measure the resistance between two wires in black Resistance value 0 45 0 60Ω __________________________________________________________________________________ NOTES ...

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