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KIPOR

KIPOR POWER

GENERATOR SHOP MANUAL

SINEMASTER

DIGITAL GENERATOR

KGE3000Ti

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Содержание KGE3000Ti

Страница 1: ...KIPOR KIPOR POWER GENERATOR SHOP MANUAL SINEMASTER DIGITAL GENERATOR KGE3000Ti ...

Страница 2: ...overhaul which includes the starting systems 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 approval for printing KIPOR POWER CO LTD reserves the right to make changes without incu...

Страница 3: ...ection of engine alert switch 26 3 4 Air filter maintenance 27 3 5 Sparkplug service 28 3 6 Adjusting of valve clearance 30 3 7 Fuel filter and fuel switch maintenance 31 4 Air filter and Muffler 32 4 1 Air filter 32 4 2 Muffler 33 5 Carburetor 34 5 1 Carburetor removal and installation 34 5 2 Stepping Motor disassembly and reassembly 35 5 3 Carburetor disassembly and reassembly 36 6 Control panel...

Страница 4: ...ke in mm 2 68 x 2 13 68 54 Horsepower 4 0 3600 rpm Compression ratio 8 5 1 Cooling system Forced air Ignition system T C I Ignition timing 25 B T D C Spark plug F7RTC Carburetor Float type horizontal butterfly valve Air cleaner Semi dry Governor Electronic control Lubrication system Forced splash Oil capacity 63 qt 0 6L Fuel tank capacity 3 43 gal 13L Starting system Recoil starter and Electrical ...

Страница 5: ...RISTICS 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 Power factor 1 0cosφ Voltage variation rate Momentary Average Average time 10 max 1 5 max 3 sec max Voltage stability 1 Frequency variation rate Momentary Average time 1 max 1 max 1 sec max Frequency stability 0 1 ...

Страница 6: ...nt temperature and humidity The output voltage will be higher than usual when the generator is still cold immediately after the engine starts AC external characteristic curve 120 110 0 5 10 15 20 25 AC output voltage Current A DC external characteristic curve 0 12 14 16 18 20 22 24 26 2 4 6 8 10 12 DC output voltage Current A 1 4 DIMENSIONAL DRAWING ...

Страница 7: ...ain winding Purple 24V winding Red Red Throttle switch DC socket Black Red Rectifier Bridge Green Charging winding Blue Blue Red Single phase socket Black Inverter unit Black White Black Green Orange Brown Yellow Gray White Black Running Indication Low oil indication Blue Orange Yellow Green Overload indication Blue Blue Black Black White White Purple Brown Gray Red Olivine Olivine Red Green Olivi...

Страница 8: ...practices 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 ...

Страница 9: ...fasteners The use of incorrect tools and fasteners will damage the engine 2 4 Electrical precautions 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...

Страница 10: ...y winding with electrical insulating tape If the wire harness has a grommet set the grommet securely Take care not to pinch the wire harnesses during installation of a part If a wire harness has damaged insulation repair by 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 ...

Страница 11: ...earance Intake Exhaust Stem OD Intake Exhaust Vessel I D Intake Exhaust Clearance of valve and vessel Intake Exhaust Seat width Intake Exhaust 0039 0008 0 10 0 02 0059 0008 0 15 0 02 215 216 5 46 5 48 215 5 45 5 47 216 217 5 500 5 518 0008 0023 0 020 0 058 00 0027 030 0 068 031 047 0 8 1 2 211 5 35 211 5 35 219 5 56 0039 0 1 0047 12 079 2 0 Valve spring Free Length Intake Exhaust 1 20 30 5 1 14 29...

Страница 12: ...ning torque Item Thread dia X pitch Ft lbf N m Connecting rod bolt M7 10 3 11 8 14 16 Cylinder head bolt M8 60 20 7 23 6 28 32 Spark plug M14 1 25 19 18 4 22 2 25 30 Crankcase cover M8 30 14 75 17 0 20 23 Flywheel nut M14 1 5 59 0 66 42 80 90 Tightening bolt of rocker arm base M6 0 75 33 14 75 17 0 20 23 Adjusting nut of rocker axis M6 0 75 7 4 8 8 10 12 M5 bolt nut 4 4 5 9 6 8 M6 bolt nut 5 9 7 4...

Страница 13: ...h Low oil alarm failure Inspect and replace Igniting device failure Inspect and replace Pulse coil Trigger failure Inspect and replace Engine does not start or hard starting Choke air inlet not controlled properly The position can be full open or half open Carburetor failure Adjust and or disassemble and clean Throttle control motor stepping motor failure Inspect Generator failure Troubleshoot Inv...

Страница 14: ...r head cover and pull the start motor rope to check if sparks jump across the Check the fuel level in the tank Loosen the drain screw and Check whether fuel reached the carburetor and check oil level No fuel Sufficient fuel Abnormal Add fuel and restart the engine Check for blockage of the fuel tube fuel filter or fuel pump Normal Dry Wet Clean the electrode and restart taking care that the choke ...

Страница 15: ...he spark plug Keep sparks and any other combustible source away from the spark plug hole C Engine does not start with sufficient oil in the crankcase Perform test using a new portfire Inspecting the resistance value of alternator ignition coil Inspecting the resistance value and the clearance of trigger Inspecting and repair or replace No spark No spark No spark No spark Normal Normal Replace the ...

Страница 16: ...re and the ground Replace the low oil alarm Disconnect Connect Disconnect Measure compression of cylinder Check clearance of trigger Enough fuel Unchoked Unchoked Unchoked Normal Normal Add oil and restart Add Fuel and restart Clean or change the oil feeding pipe Disassembly and clean Oil alarm Choked Choked Choked Abnormal 1 Check if the clearance of valve is proper 2 Check if it accumulates t o ...

Страница 17: ...ean electrodes and adjust the spark plug gap or replace a new spark plug Disassemble and clean Abnormal Clogged Abnormal Abnormal Not clogged Normal Normal Normal Normal Not clogged Check the AC output Abnormal Check control motor for throttle valve Abnormal Replace the control motor for throttle valve Replace the inverter unit Normal Normal Abnormal Check the AC output Check the throttle control ...

Страница 18: ...als of the rectifier 4P connector Resistance value 0 12 0 15Ω Abnormal Check the wire harness input line replace the stator Normal Rotor lose magnetism replace rotor Is the overload indicator light ON Is the engine speed normal Engine speed Smart switch ON 3000 100rpm Smart switch OFF 3600 100rpm Engine stopped and check AC receptacle Replace the inverter unit OFF Normal Normal Normal Disconnect t...

Страница 19: ...k the starting motor Abnormal Replace the starting motor Normal Check repair or change main harness wire K Starting Battery Will Not Hold a Charge Replace ignition coil Check ignition switch Abnormal Normal Check charging adjustor Abnormal Replace charging adjustor Normal Measure resistance value of charging winding Resistance value 0 19 0 21Ω Abnormal Check repair wiring harness of alternator and...

Страница 20: ...lve clearance Check Adjust Fuel tank and filter Clean Fuel line Check Every 2 year Replace if necessary Note Interval operating time in normal troubleshooting When it is used in dusty place filter should be cleaned every 10 hours or everyday Maintenance should be carried out by the qualified technicians 3 2 Engine oil 3 2 Engine Oil A Checking Oil Level Engine should be shut off and generator be o...

Страница 21: ...il limit level 4 Reinstall the dipstick and screw it tightly 3 3 Inspection of the Oil Alert Switch 1 Disconnect the orange connection of the oil alert wire when engine is running and ground one end to the engine block as shown below to ensure that the engine will stop when the oil alert lamp is lit NOTE On early models the oil alert connection is in the back of the generator on the opposite side ...

Страница 22: ...s working properly if there is normal conductivity 3 4 Air Filter Maintenance 1 Open the service door 2 Open the cover of air filter and take out the filter element 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 4 Reinstall...

Страница 23: ...is chipped or cracked 3 Remove carbon or other deposits with a stiff wire brush Check if the sealing washer is damaged 4 Check the resistance of the spark plug and replace it if it is not within the specified resistance value Resistance of spark plug 3 9KΩ 5 Use a feeler gauge to check the electrode gap Adjust the electrode to the following specification by carefully bending the side electrode to ...

Страница 24: ...l engine 1 Remove valve cover cylinder head cover Gasket of 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 on the air guiding cover mark scale 3 Insert a feeler gauge into the gap between rocker and valve to measure the valve clearance Valve Clearance Intake 0039 0008 in 0 10 0 02mm Exhaust 0059 0008 i...

Страница 25: ...on Keep smoking materials and any open flames away during fuel system maintenance Make sure that there is no leaking fuel after service 1 Drain all fuel from the tank and carburetor and remove the fuel tank 2 Loosen the nuts between fuel switch and fuel tank and remove the filter element 3 Turn the fuel switch to the open position Clean it with a suitable solvent then blow dry with compressed air ...

Страница 26: ...ion to inner and outer sides Filter element 4 2 Muffler Disassembly and assembly Muffler syphon assembly Clean the carbon inside muffler syphon using the brush before installing assembly Clean the carbon using the brush before installing Muffler gasket Exhaust pipe gasket Cover of muffler assembly knock it to remove carbon inside by using rubber hammer before installing Muffler Fireproofing cap ...

Страница 27: ...k of carburetor Carburetor gasket A Carburetor assembly Carburetor gasket B Rope of air choke Air choke weldment Gasket of carburetor Air filter bottom case Filter element Air filter cover Reassembly Check if there is any damage in the gasket before assembly Reassembly Check if there is any damage in the insulator block before assembly Reassembly Check if there is any damage in the gasket before a...

Страница 28: ...ping motor disassembly and reassembly stepping motor stepping motor base fork disassembly hold it tightly for fear that the spring will lose when it is disassemblied fork spring fork fuel control lever fork spring ...

Страница 29: ...ontrol needle Needle base Reassembly Inspect the abrasion of the head and the action of spring then install it Reassembly Clean channels with compressed air before installation check if it is a proper direction Main jet Reassembly Clean channels with compressed air before installation Float Seal ring of fuel cup Reassembly Check for smooth movement after installation Float chamber Bolt of float ch...

Страница 30: ...ohm meter to ground and measure the resistance in the various 10p connector pins to measure the resistance Use the following chart for reference Color Circuit unit Specified resistance value Blue Primary ignition coil 0 8 1 3Ω Orange Low oil alarm It is not lit under the condition that oil position is normal Yellow Trigger coil 80 130Ω Kelly Grounding wire Put through Green Ignition device power c...

Страница 31: ...th standard listed in the following table Positive Electric pen Negative Electric pen 1 2 3 4 1 Block Block Block 2 Connect Block Block 3 Connect Connect Connect 4 Connect Block Block 3 Negative terminal 1 Negative terminal 2 AC terminal 4 AC terminal E Charging adjustor Start the engine and disconnect the wire of charging adjustor with two electrodes of the battery then measure the voltage betwee...

Страница 32: ...cover Framework weldment Housing weldment Housing door weldment Chassis assembly Control panel Inverter unit Starting relay Accumulator Air drain bar Door lock components Oil dipstick Assembly Check if the float is rotating smoothly before assemly Damping cushion of bottom base Damping cushion Reassembly Check if the damping cushion is aging or rupture before assembly Oil drain plug Fixing board o...

Страница 33: ...urface of rotator before installation Rotator B Inspection 1 Ignition winding Measure the resistance between green wire and olive wire Resistance value 0 26 0 28Ω 2 Outer use charging winding Measure the resistance between two blue wires Resistance value 0 12 0 15Ω 3 Built in charging winding Measure the resistance between two purple wires Resistance value 0 19 0 21Ω 4 Sub winding Measure the resi...

Страница 34: ...ng board 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 Sub resistance 15 21KΩ ...

Страница 35: ...tment Adjust the clearance between trigger and salient of the rotor clearance of trigger 0 020 0 030 in 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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