KGE100Ti Shop Manual
Contents
1. b IG2000s CG2000s Wey DDDDDD UA f i 1 5 WIRING DIAGRAM a 1G2000 IG2000s b 1G2000p c CG2000 CG2000s 2 Service information 2 1 The importance of proper servicing BM Proper servicing is essential to the safety of the operator and the reliability of the engine Any error or oversight made by the technician while servicing can easily result in faulty operation damage to the engine or injury to the operator A warning E Improper servicing can cause an unsafe condition that can lead to serious injury or death Follow the procedures and precautions in this shop manual carefully HM Some of the most important precautions are given below However we cannot warn you of every conceivable hazard that can arise in performing maintenance or repairs Only you can decide whether you should perform a given task A warning E Failure to follow maintenance instructions and precautions can cause you to be seriously hurt or killed Follow the procedures and precautions in this shop manual carefully 2 2 Important safety precautions Be sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing a2. Engine switch Check the continuity of connector there should be continuity if presses down the micro switch otherwise disconnect the switch Press down y eg A d ai WA ve y A N S Aero receptacle parallel UO communication port Check the continuity between connector and aero receptacle there should be continuity between the two terminals with the same serial number 36 8P connector Aero receptacle 9 8 6 3 Black Red Yellow Blue e E F 4 INN Continuity between the CL UTI same two serial numbers a eee ae ae fi SE Ben 9 White Purple Orange Green 1 2 4 7 8P connector Aero receptacle Aero plug Parallel UO communication data wire Check the continuity of aero plugs there should be continuity between two plugs with the same serial numbers Parallel communication port Aero plug 2 1 7 4 4 GEI e ES ae es 8 lu a WN Continuity between the Ir EE e e same two serial numbers ee EE r Ee TE a ni a 3 9 8 6 3 Parallel output receptacle Check the continuity between the two terminals of parallel output receptacle 37 Parallel output cable 1 Check the AC receptacle output terminal there should be no continuity between two terminals 2 Connect the AC receptacle output terminal with one lead check the parallel plug there should be continuity among the four plugs 3 There should be continuity between the cable earth terminal and AC re
3. 1 35 1 75 5 0 5 5 0 18 0 21 0 65 0 90 5 Trigger Attach the two testers in the trigger and measure its resistance Trigger resistance 80 1300 50 9 3 Adjustment Adjust the clearance between trigger and the projection part of rotor Trigger clearance 0 50 0 75mm 27 A Insert a feeler gauge between the trigger and the projection part of the rotor loosen the trigger fixed plate bolt to adjust the clearance slightly Never move the plastic part of trigger to avoid it separates from the fixed plate and damages the trigger 51 10 Cylinder cover Rocker arm 10 1 Disassembly Reassembly ki AN ZA Ge DIN I a i V i S il d EE EE Lu d Cylinder cover i E 1 WI E E i D Se Bi d i H Ee d n ING e Y Se RO a KS ee iS i Hi i i Adjusting nut of valve clearance Adjusting screw of valve clearance S i x i if tH Ss i i FER SOLA MEA SEA pi e aay O Rocker arm cl Rocker arm of inlet valve GI Se t V Rocker arm of exhaust valve Ul iT I Welding part of breather cover a if TICA X e Al Seal gum with diameter of 1mm St i DON er 7 i E II Cylinder cover my i Sere Oe SLAVI ta 4 i 3 i i Ge i i i I II 9 di at dE a e i i iui ck EAT di fin il a I i VALE d 7 fl I I gt il amp d f e Se
4. Front cover and control panel Right Left side cover 2 Disconnect the fuel tube from the fuel tank and remove the fuel filter 3 Remove the clogged foreign material from the fuel filter and check the fuel filter for damage Replace the fuel filter if necessary 4 Remove the fuel tank and clean it with cleaning solvent and allow the fuel tank to dry thoroughly 5 After cleaning install the fuel tank and set the fuel filter in the tank Connect the fuel tube 6 Install the removed parts in the reverse order of removal 7 Fill the fuel tank with gasoline and check the fuel tube for gasoline leakage f Sp 4 SH D dk SH Fuel tank i h A x lt D Fuel filter i Hoop Fuel tube 3 8 Fuel tube Fuel pump Caution Mi Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Keep heat sparks and flame away Wipe up spills immediately 1 Drain the fuel from the tank and carburetor and then remove the following parts Rear cover Front cover and control panel Right Left side cover 27 2 Check the fuel tube for deterioration cracks and gasoline leakage If there is any abnormality in the fuel tube replace the tube 3 Check the diaphragm tube for deterioration crack and oil leakage If there is any abnormality in the diaphragm tube replace the tube 4 Check to see whether water or foreign material has been accumulated in the fuel pump
5. Standard resistance Replace the stepping motor if the resistance excesses the above range A 33 6 Control panel 6 1 Removal Installation 34 IG2000 IG2000s IG2000p CG2000 CG2000s 6 2 Inspection a Control panel AC receptacle Check the electrode contact disk inside receptacle if it is burnt or the color changes replace for it DC receptacle Connect both terminals of the receptacle with a jumper wire to short There must be continuity between the lead wire terminals with the circuit protector ON Replace the DC receptacle if there is no continuity Smart switch LOAD SELECT Switch CG series There should be continuity with the switch ON and no continuity with the switch OFF ignitor Pull off the 10P receptacle from ignitor measure the resistance by connecting one testing pen with the metal outer case of engine and the other testing pen with the 10P connector Standard resistance Primary coil of the ignition coil 0 8 1 30 i There should be no continuity with correct Orange Oil level alarm oil level il lev Trigger coil 80 1300 Yellow Green Continuity Ignitor unit power coil winding 0 26 0 280 There should be no continuity with the Engine switch Rea g switch ON continuity with the switch OFF 35 X eten A IAI LIO GI dp il Edo Ergo cli E SUO gi DI N d ALIA Ar AL LI SE ae oe Red Orange Yellow Yellow Green Blue Green Engine switch
6. If there is water or foreign material accumulated in the pump replace the fuel pump 5 Check the fuel switch and fuel duct blow away the foreign matter with high pressure gas with oil switch turned on 6 After assembly check for gasoline leakage from each part Fuel pump Fuel tube Diaphragm tube to Carburetor SE to pressure port Fuel tank LI d Sa Fuel switch Fuel tube 3 9 Spark catcher Caution BM Do the performance after engine cooled completely 1 Remove the rear cover 2 Disassemble the spark catcher from muffler 3 Remove the carbon from the spark catcher steel net check for damage and replace it if necessary 4 Install the removed parts in the reverse order of removal SS Lc DY WH 28 4 Muffler Caution BM Muffler removal installation must be performed with the engine cold Disassembly Reassembly Muffler Installation Remove the carbon deposits by lightly i tapping with a rubber hammer before installation Spark catcher s ests s Muffler Gasket Installation Remove the carbon deposits with a brush before installation S Sealing strip ofrearcover Rear cover 29 5 Air filter Carburetor Caution Loosen the drain oil bolt and drain out fuel before disassembly E Keep heat flame and sparks away 5 1 Disassemblv Installation of Air filter Breather pipe Carburetor gasket 7 D ee E Ks pices E
7. 13 00 12 95 Height h 0 97 0 99 0 87 Ring side clearance 0 02 0 06 0 15 1st ring Ring end clearance 0 15 0 25 i 1 95 2 15 1 75 a ere CH CH 1 07 Piston ring 2nd ring 0 15 Ee sin 024 7 3 rod Big end LD 24 020 24 03 24 09 Crankshaft Crank pin O D 23 967 23 980 23 90 Valve 0 10 0 02 clearance 0 15 0 02 e iena 3905 3980 390 3 955 3 970 3 90 Guide 1 D IN EX 4 000 4 030 4 06 IN EX Valve spring Free length IN EX 24 9 Cam wheel Cam height 29 026 29 086 28 5 pO 8966 8975 8 92 Camshaft Camshaft bearing LD 9 000 9 015 9 035 000 Connecting Small end LD 13 006 13 017 13 08 i 033 6 097 Rocker arm 5965 aint os Carburetor Foai de Piet screw opening 2iumso SE ee o607 resistance Drang osma _ Secondside LE Puse coi Aigeg osos roge Resistance proa li NO CO Do hi Motor Standard Q IG series CG series Part Hem 120 230V 24 230V 240 120V OV V Ignition winding Resistance Green Yellow Green 0 40 0 55 Outer charging Blue Blue 0 12 0 15 winding ua White White IG Sub winding White White CG 0 15 0 30 Black Black Black ue 0 18 0 0 65 0 Main winding Resistance Black Yellow Black Gr 5 0 5 5 allt l 21 90 een Black Red CG 2 6 Torque values M5Bol nut 58 0608 Note Use standard torque values for fasteners that are not listed in this table 2 7 Troubleshooting
8. 2 Insert the spring into block location hole set the chain pressure plate into cylinder block and spring into location hole Pay attention that the spring pin should be inserted as far as location 3 Adjust the block location to align the block bolt hole with cylinder block bolt hole 4 Install the inner hexagonal bolt and tighten it 5 Hold the spring free end to seize the block as picture shows knock the spring pin with copper hammer 56 f l pya d y gt k li de i INI Wp PN del Clamp the spring with i d i sharp nose pliers to seize the block 11 5 Assembly of crankcase cover 1 Clear the remaining seal gum on the cylinder block and crankcase cover with cloth 2 Smear seal gum on the cylinder block sealing face as picture shows 3 Reassemble the crankcase cover in the opposite direction of disassembly Caution Install the crankcase cover on the cylinder block 3 minutes after smearing Revolve the crankshaft if necessary 57 4 Tighten the crankcase cover bolt slowly screw to the prescribed torque 5 Wait for 20 minutes after installation never refill in oil or start the engine during these 20 minutes Cylinder block Sealing gum with diameter 1 5 to 2mm Gi 11 6 Inspection Inspection of oil alarm 1 Stand the oil alarm check the oil alarm output wire and copper earth wire there should be no continuity 2 Bottom up the oil
9. Lubricate any sliding surfaces before reassembly 6 6 After reassembly check all parts for proper installation and operation 7 Many screws used in this machine are self tapping Be aware that cross threading or over tightening these screws will strip the threads and ruin the hole 8 Use only metric tools when servicing this engine Metric bolts nuts and screws are not interchangeable with no metric fasteners The use of incorrect tools and fasteners will damage the engine 9 Follow the instructions represented by these symbols when they are used E Electric precautions 1 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 2 Check the connector terminals for bend excessive extrusion missing terminal or other abnormalities before connecting the connector 3 To connect insert the connector as full as it goes If the connector is a locking type be sure that it is locked securely 4 Check the connector cover for breakage and check whether the connector female terminal is open excessively Then connect the connector securely Check the connector terminal for rust Remove the rust using an emery paper or equivalent material before connecting the connector 5 Set the harness clips in the specified places of the frame securely and clamp the wire harnesses 6 Clamp the cables securely 7 Clamp the wi
10. Remove carbon or other deposits with a plug cleaner or stiff ire brush Check the sealing washer for damage 3 Measure the plug resistance replace the spark plug if the measure is not accord with the asked valve Spark plug resistance 3 9KO 4 Measure the plug gap with a wire type feeler gauge Adjust by bending the side electrode if the measure is not accord with the asked valve Spark plug clearance 0 6 0 7mm Standard spark plug A7RTC 0 6 0 7 _ 1 5 Install the plug finger tight to seat the washer and then tighten with a plug wrench Torque valve is 12 15 N m 24 3 6 Valve clearance Caution WE Valve clearance inspection and adjustment must be performed with the engine cold Inspection Adjustment 1 Remove the following parts Front cover control panel Rear cover Right left side covers Fuel tank Inverter unit engine bed Recoil starter fan cover Inlet Exhaust side baffler 2 Remove the four tighten bolts and disassemble the cylinder cover Don t remove the cylinder cover with excessive force It can deform the cylinder cover Replace the cylinder cover if it is deformed EA Cylinder head cover 3 Turn the rotor to set the piston at top dead center of the compression stroke Timing line of camshaft driving chain should align with the cylinder head seal check whether the inlet and exhaust valve are closed Timing marker E
11. black terminal and white terminal 1 Check and repair stator wire Abnormal _ harness or replace stator 2 Rotor inner magnetism decreases replace the rotor Normal Replace the inverter unit 16 Measure voltage IG series CG series Phase wire color Phase wire color Model Black Black Black Yellow Green Red Sub winding color Neutral wire color Black Item White White Sub winding color Black Green 120V 230V 240V 120V 230V 240V Voltage between 0 30V IT 60V O 15V 0 30V phase wires Sub winding Div voltage i No AC output CG series Is th d 1 Abnormal Perform the throttle control system s the engine speed normal GE Normal Abnormal Check the DC output Replace the DC receptacle Norma Abnormal Check the DC output Replace the rectifier Normal Measure the resistance between the Abnormal Check the wire harness or replace blue terminals of the rectifier the stator Resistance 0 12 0 150 Rotor losses magnetism and replace the rotor j No DC output k Parallel no output BM Make sure that the two PARALLEL I O are connected correctly by special communication wire BM Make sure that the PARALLEL OUTPUT are inserted into the parallel cable and connected correctly BM If there is any disconnection when you start the parallel generators some one will be no output and 17 damaged A warning BM The parallel cable is only used for 2 generators with
12. eee Ton Installation Checkthe KEE gasket curve or damage Airfitershell andpayattentontothe inside or outside direction Fine filter element Rough filter element Air filter cover 5 2 Disassembly Installation of Carburetor Air filter shell E SE Negative pressure tube CarburetorgasketA Ee EE Sea i Installation check the gasket for damage before installation Inlet pipe gasket A Cela Installation check the gasket for curve and Carburetor screw damage pay attention to the Carburetor insulation block Hoe and outside direction Installation A check the insulation block for Ollinlet pipe GES before installation cri 30 Disassembly Installation of Stepping motor _ Stepping motor cover Paes 1 i il ne Stepping motor Stepping motor seat S 4 i Fork spring Fi i Ir ere Disassembly K l heat aa Fork hold the spring firmly l A i E i to avoid missing SE d ak Fork 3 Throttle level Fork spring e i d Li 31 Disassembly Installation of Carburetor Choke valve Fork Fork spring dee E t illChockvalvesheet ASR i SE es i I J 2 W i Sek 3 J i r l PE E i Li i i l Carburetor block Mixed radio adjusting screw ini My Installation check the Adjusting spring e K ek fi GE d S lii TE EE f ont end for damage We Li j a before installat
13. ili N LE G Ee ji i amp x ee il es i podi op A y A Gs l i a SE I Ne sail 52 10 2 Inspection Rocker arm outer diameter Standard mm Service limit mm 5 972 5 980 5 965 Rocker arm inner diameter of inlet exhaust valve Standard mm Service limit mm 6 000 6 012 6 037 Li l Inner diameter of rocker arm bearing Standard mm Service limit mm 6 000 6 012 6 037 53 11 Crankcase Cover Cam timing drive chain 11 1 Disassembly Spark plug SE Si Chain pressure plate Spring Cam timing drive chain wheel Roller chain Drive shaft i lt Osealring Crankcase cover Clip block Location pin of crankcase cover _ i L I Pin Spring pin shaft ics H Support plate of chain ca a e S f ien E x o GN ba a a 11 2 Crankcase cover Y E ae Sa Oil alarm 2 SS a See E AR a x ZARA xl O seal rin 3 oh ir 2 2 Set oh ES N gi PONS MA d Nu d f i d _ Oil gear shaft Crankcase cover RA S A S oi Speed limitation gear gasket A oe Oil gear Retainer ring 54 11 3 Reassembly of roller chain 1 Install the crankshaft piston and connection rod assembly on the cylinder block 2 Revolve the crankshaft align the timing mark of crankshaft timing shaft with the timing mark of crankcase Step 1 3 Install the roller chain on th
14. inverter unit Cross protection frame of left Protection sleeve housing case Gasket Fixed seat of pulling handle 40 Left housing case Left housing case d Fuel pump Fuel switch handle Fuel switch Smart switch Smart switch baffle Fuel pump Fuel pipe III Left housing case Diaphragm tube Fuel pipet Fuel tank Fuel switch Fuel pipe I SS Clip e ua Int ji IC ee EE 41 7 3 Fuel tank Caution BM Gasoline is highly flammable and explosive You can be burned or seriously injured when handing fuel Keep heat sparks and flame away Wipe up spills immediately Loosen the drain screw to drain the carburetor thoroughly before removal Fuel tank Capacity 3 5L Installation iclear the dirty and water at the bottom before installation junk i i i H ui Ia RI Dire Oil scale Filter bowl Ventilation valve DI i O ring SC Fuel tank cover Fuel tank port gasket gz fu Se E a H 4 i Seal ring of fuel tank cover SC Sata Ventilation filter A Inner cap Po LI Spring A i sun P Washer l x d i fl Go Lock pin rae Aa II i ua il Il IS Way l IN Ly Cross protection bracket of right housing case Filter gauze The left and right assembly can t be mixed La Anchor ear Cross protection bracket of left housing c
15. the spark test using a new ignitor Replace the ignitor No spark Good spark Check the engine switch Replace the engine switch No spark Good spark Disconnect the low oil alarm and perform spark test Replace the low oil alarm No spark Abnormal Check the resistance of motor ignition winding Replace the motor stator Normal Check the trigger Abnormal _ Replace the trigger or readjust trigger clearance Normal Check the ignition coil resistance Abnormal and high pressure cable high pressure insulation cap Normal Inspection or replace wire harness d Engine oil level is low but engine does not stop Poor oil alarm device Replace the oil level alarm Replace the ignition coil Drain out oil completely disconnect alarm No continuity connection wire and check the continuity between alarm outlet terminal and ground Continuity plug and check the continuity between the plug orange wire and ground Continuity Ignitor fault please replace the ignitor 13 e Engine stops running Throttle is at the correct position Oil alarm Check the oil level and oil alarm Fill in oil and restart the engine Sufficient oil Reset the alarm connection wire disconnect ignitor plug and check the continuity between the plug orange wire and ground No fuel Fill in fuel and restart the engine Sufficient fuel Check the f
16. N SHIELD IGNITION COIL 8 1 DISASSEMBLY ASSEMBLY 8 2 RECOIL STARTER 8 3 INSPECTION 9 GENERATOR TRIGGER 9 1 GENERATOR 9 2 CHECK 9 3 REGULATE 10 CYLINDER COVER ROCKER ARM 10 1 DISASSEMBLY ASSEMBLY 10 2 INSPECTION 11 CRANKCASE COVER CAM TIMING DRIVING CHAIN WHEEL 11 1 DISASSEMBLY 11 2 CRANKCASE COVER 11 3 ROLLER CHAIN 11 4 CHAIN PALLET AND PRESSURE PLATE 11 5 CRANKCASE COVER 11 6 INSPECTION 12 CRANKSHAFT PISTON 12 1 DISASSEMBLY ASSEMBLY 12 2 PISTON 12 3 INSPECTION 1 SPECIFICATIONS 1 1 SPECIFICATIONS Dimensions and weights Model 1G2000 1G2000p CG2000 1G20005 CG2000s Overall Length Overall Width Overall Height Net Weight 22Kg 24Kg Engine Model KG158 Type Displacement Bore x stroke Maximum horsepower KVA Compression ratio Cooling system Ignition system Ignition timing Spark plug Carburetor Air cleaner Governor Lubrication system Oil capacity Starting system Stopping system Fuel used Generator Model Generator type Generator structure Excitation Voltage regulation system Phase KD20 KD20A KM20 KM20A Multi pole rotation type Self ventilation drip proof type Self excitation Magnet type PWM Plush width modulation Three phase Rotating direction Frequency regulation Clockwise Viewed from the generator AC DC AC conversion Inverter type 1 2 CHARACTERISTICS IG2000 IG2000s IG2000p CG2000 CG2000s Maximum output AC 2 0KVA Rated output AC 1 6KVA Rated outpu
17. Preface This manual covers the construction function and servicing procedure of KIPOR 1G2000 IG2000p IG2000s CG2000 CG2000s generators Careful observance of these instructions will result in better safer 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 incurring any obligation No part of this publication may be reproduced without written permission CONTENTS 1 SPECIFICATIONS 1 1 SPECIFICATIONS 1 2 CHARACTERISTICS 1 3 PERFORMANCE CURVES 1 4 DIMENSIONAL DRAWINGS 1 5 WIRING DIAGRAM 2 SERVICE INFORMATIONS 2 1 THE IMPORTANTANCE OF PROPER SERVICE 2 2 IMPORTANT SAFETY PRECAUTIONS 2 3 SERVICE RULES 2 4 SERIES NUMBER LOCATION 2 5 MAINTENANCE STANDARDS 2 6 TORQUE VALUES 2 7 TROUBLESHOOTING 3 MAITENANCE REGULATE 3 1 MAITENENCE SCHEDULE 3 2 ENGINE OIL 3 3 OIL ALARM 3 4 AIR CLEANER 3 5 SPARK PLUG 3 6 VALVE CLEARANCE 3 7 FUEL SWITCH FUEL FILTER 3 8 FUEL TUBE FUEL PUMP DIAPHRAGM 3 9 SPARK ARRESTER 4 MUFFLER 5 AIR FILTER CARBURETOR 5 1 AIR FILTER 5 2 CARBURETOR 5 3 INSPECTION 6 CONTROL PANEL 6 1 CONTROL PANEL 6 2 INSPECTION 7 LAMP CHIMNEY SIDE COVERS FUEL TANK GUIDE PLATE INVERTER UNIT 7 1 LAMP CHIMNEY 7 2 SIDE COVER 7 3 FUEL TANK 7 4 FAN SHIELD ENGINE FIXED PLATE 7 5 GUIDE PLATE 7 6 INSPECTION 8 RECOIL STARTER FA
18. a General symptoms and possible causes Engine does not start or hard staring Spark plug faulty Inspect and replace Trigger faulty or trigger clearance faulty Ignition winding faulty Throttle opening fault Set in fully close or half close position Carburetor faulty Adjust and or disassemble and clean Engine speed Sen Throttle control motor stepping Inspect and replace motor faulty stabilize too al F gn nverter un nspect and replace high or too low SRO To H Valve clearance misadjusted Readjust b Hard starting Check the fuel level in the tank NO tue Add fuel and restart the engine aen fuel Loosen the drain screw and heck whether fuel reached the arburetor Good spark Add fuel and restart the engine Remove the spark plug and heck for wet or fouled electrode Check for blockage in the carburetor port and nozzle Clean the electrode and restart Wet taking care that the choke is not losed too much If flooding is severe heck the carburetor float valve No spark or Remove the spark plug and weak spark heck for wet or fouled electrode Perform the ignition system roubleshooting ses spark Low cylinder Install a compression gauge in __Compression 1 Check the valve clearance he spark plug hole and check the 2 Check for carbon deposits in the ylinder compression by pulling combustion chamber he recoil starter rope several imes 3 Check for va
19. alarm check again there should be continuity 3 Bottom up the oil alarm completely in the oil check the float there should be no continuity Cam height Standard mm Service limit mm 29 026 29 086 28 15 58 Cam inner diameter Standard mm Service limit mm 9 000 9 015 9 035 i Camshaft outer diameter Standard mm Service limit mm 8 966 8 975 8 920 Decompression block Check the return spring for damage and weary make sure the decompression block could perform well Decompression block Return spring 59 12 Crankshaft Piston 12 1 Disassembly Reassembly Valve spring seat Valve spring ECH j a i Disassembly SE press down the f l spring seat if ee Oil seal of inlet valve pipe Slightly and i disassemble it _7 Inlet valve pipe Outer washer of exhaust valve pipe Exhaust valve pipe H Cylinder block pani u be ul jl Piston ENN Assembly JM install the piston with the A label Gar E i towards the side motor ar dA T Sec E ZS SE sa Crankshaft i eating oa ho L SE ui SS EE Assembly F i NR ua an E Pay attention not to damage the oill 8 oe DO Ca d seal push it until the bearing N EE en touches the bearing seat bottom i ae eg Ce EE niet valve seat i gl PRIA Exhaust valve seat o Rc O SC E Se Exhaust valve Cali Inlet valve o e As
20. ase d Fuel tube 42 7 4 Fan shield Engine fixed plate 7 5 Guide Plate 7 6 Inspection 1 Aluminum shell resistor CG series Measure the resistance of aluminum shell resistor Measuring error is 5 Model 120V 230V 240V Resist SITA 50 50W 100 50W consumption power 2 Capacitor CG series Measure the capacitance Measuring error is 5 Model 120V 230V 240V Capacity pressure 40uF 250V 20 uF 250V 43 A4 8 Recoil starter Air conduct cover Ignition coil 8 1 Disassembly Reassembly Seal sheath ay Ignition coil Air conduct cover Recoil starter Rectifier bracket Rectifier Starting pull rope Installation check the starting pull rope for crack i Recoil starter spring Starting handle cover and damage before installation CALISTA e ATI LA SEA N De pi ate Disassembly Starting handle Put on glove to operate and take care not to allow the recoil starter Ee spring to pop out ip CH D I D Starter outer shell Installation Hang the outer hook into the reel groove and the inner TE hook on the jackcatch of outer shell Starter reel Installation Install the starter spring onto reel then jinstall reel on the starter outer shell Friction spring e Pallet guide plate i l B Spring cap Pallet spring eil GE Pallet We 45 8 2 Installation of recoil starter 1 Set the spring into the starter reel and hang the spri
21. ceptacle earth terminal Parallel plug di a SZ ii W Rio f ch I Parallel plug SES Earth terminal A ni ay un H DKW Earth terminal Earth terminal if 3 j 2 a sA i gt TI win Output terminal K da all a y AC receptacle 38 7 Lamp chimney Housing case Fuel tank Batter Inverter unit 7 1 Disassembly and installation of lamp chimney Caution E Stop the engine and cool the lamp chimney completely before disassembly Asbestos pad of lamp shell swivel Lamp shell handle il i M A Lamp shell B te Y Lo i de 0 Wie vi i 4 f K hy a A i d e D NI SL Ky SPE Li l A Switch Left fixed bracket of lamp shell i om a 39 ar Asbestos pad of lamp shell handle Filament fixed seat Reflector N Glass i Lamp tube Seal ring of lamp shell A Lamp cover ga cd SS Nut Lamp shell swivel 7 2 Disassembly and installation of housing case Top cover Right housing case Plug in EA n D Ge Fuel tank cover Fuel tank port gasket ata Hh gle 4 3 gt H ba Left housing case ta H d ao n d H Cross protection HE IL ui frame of right d a housing case D d ant ol Side door subassembly Ki ne le EE STA n Hi n G T Ae itd e S t i e A l WK dci Split washer de Inverter unit A CIA x Shock pad of SE
22. d 2 ring Check the piston ring for flexibility after installation Stagger each piston ring opening apart piston pin for 120 61 The 1st ring with chrome a AE The 2nd ring Parkerizing on the surface 7 A ta Oil ring i Se se Ci 12 3 Inspection Free length of valve spring Standard mm Service limit mm 26 4 24 9 Valve seat width Standard mm Service limit mm 0 7 1 8 SP PSSA SSA SAARI Sf Valve rod outer diameter Standard mm Service limit mm Inlet valve 3 965 3 980 3 90 Exhaust valve 3 955 3 970 3 90 62 Valve guide pipe inner diameter Standard mm Service limit mm Inlet Exhaust valve 4 000 4 030 4 060 JAA A7 N W a Clearance between valve rod and valve guide pipe Standard mm Service limit mm Inlet valve 0 020 0 065 0 10 Exhaust valve 0 030 0 075 0 12 Cylinder inner diameter Standard mm Service limit mm 58 000 58 020 58 105 63 Piston skirt outer diameter Standard mm Service limit mm 57 960 57 980 57 850 10m Clearance between piston and cylinder Standard mm Service limit mm 0 020 0 042 0 120 Side clearance of piston ring Standard mm Service limit mm 0 02 0 06 0 15 Piston ring end clearance Locate the piston ri
23. e cam timing drive chain level the timing mark upward Step 2 4 Put the roller chain into the crankcase set the end of roller chain to the crankshaft timing gear Step 3 straighten the chain to align the timing mark of cam timing drive chain with cylinder head sealing face Caution Don t remove the timing mark of crankshaft timing gear during installation If the timing mark of cam timing drive chain is not parallel with cylinder head sealing face adjust the meshing of chain and cam 5 Install the O seal ring into the drive shaft and then assemble the drive shaft Step 4 Pay attention that the opening of drive shaft should upward 6 Install chain pressure plate Step 5 Timing mark e ee Installation sealing face wh ON qi Ai ij Timing mark on the crankcase block 11 4 Assembly of chain support plate pressure plate Chain support plate 1 Put the upper groove of chain support plate into block press the other end to seize the support plate fully 2 Insert the location pin into cylinder block location hole and align them set the support plate and clip block into cylinder block Adjust the clip block location to align the clip bolt with cylinder block bolt 3 Install inner hexagonal bolt and tighten hard E Press hard dead i 1 AM Nua a am Wu D Chain press plate 1 Install the spring pin shaft spring and chain pressure plate as the picture shows
24. h or months or months or year or 100 Hrs 300 Hrs month or operating hour interval whichever comes first een e __ __L_L___ Replace e e ES SE heck Air filter SE Spark plug Clean Adjust Spark catcher Clean EH Fuel tank and filter Clean Every 2 year Replace if necessary Note 1 For commercial use operation hours are determined by proper maintenance 2 Service more frequently when operating in dusty areas every 10 hrs or every day 3 Service by KIPOR authorized agency unless correct tools or professional specialist is available Do service according to the manual 3 2 Engine oil m Checking for the oil level Stop the engine and check the oil level be sure to put the engine on a flat floor when checking 1 Loosen the screws of the maintenance cover and remove the cover 2 Remove the oil filler cap and check for the oil level Maintenance cover Cover screw 20 Upper limit Oil dipstick pp Lower al Drain oil port 3 If the oil level is low add to the edge of the oil filler port E Replace the engine oil 1 Disassemble the oil dipstick and oil drain bolt drain out dirty oil 2 Fix the oil drain bolt tightly 3 Refill in clean oil oil capacity is 0 4L O Recommended oil SAE10W 30 or SAE30 API Service Classification SE SF or SG 4 Check the oil level fill to the upper limitation level if necessary 5 Tighten the oil dipstic
25. ion d fl ee l t i eTO DRE i p UI E CIE o Idle fixed screw SE o ot PRA RU gt dI d bo t De i il I SE E A aoe d JE Needle seat oam tube ay Installation GE Oil control needle clear the foreign matter with 33 i di Installation compressed gas before sl De check the end and spring before installation pay attention to installation the installation direction __ tf NEEN a Oil control needle spring Main metering orifice hi 3 ISP Sh re co SIN Ke fe i NEE E Installation _ Oil cup seal ring i clear the foreign Be ee Se 3 matter with compressed gas Pe before installation Ce Float pin Li Ip Float S H Installation E touch the check the float before installation f AN il Uu i n S 1 Oil cup Oil cup fixed screw seal ring BS d e EE Drain oil bolt of oil cup UR Do o NENO Ee ar Installation bey check the fuel leakage AeA check the fuel leakage before installation i pa de SS petore installation lie SE i A i M OG 32 5 3 Inspection Float height Place the carburetor as the picture shows measure the float height between float and carburetor block Height 12mm Replace the float if the float height is not the right size A Float e bh Stepping motor Measure the resistance of stepping motor lead out wire Between 1and 3 45 550 Between 2 and 4 45 550
26. k m 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 container to your local recycling center or service station for reclamation Do not throw it in the trash pour it on the ground or down a drain E Drain the used oil while the engine is warm Warm oil drains quickly and completely Be attention that the temperature should not be too high to avoid scalding 21 3 3 Checking for the low oil alarm 1 Disconnect oil alarm connector when the engine is still running connect the two plugs be sure that oil alarm lights and engine stops yoii i eaten SE i fit th pf ke IZ A f I i i 1 bk i i pt i I i NEE d i A 1 i D Z vu 3 ege hill WH ten LE d bo p 1 V E a d SI F d gt ae Bl ENEE f La Ge ei e sm A gt at ee no E Orange Yellow green Orange Ignitor outlet terminal the two plugs are connected Alarm outlet terminal 2 Stop engine disconnect oil alarm connector check the connector conduction no conduct is normal e dea Io d d I RY A rece Ee de EZIO el mazione iN d Le e E ol s E H ET at y it zg Si i Tala o X 1 A Ri bk e al 3 jae A ae j Dee E ts Foe H SE e Ignitor outlet terminal Alarm outlet terminal check the conduction between the two wires 3 Drain out the oil inside engine and check the conduction conduc
27. lve cone and base 4 Check for worn piston piston ring or cylinder Normal compression Install the spark plug securely Restart the engine according to he starting procedure E Cylinder compression check 1 Remove the spark plug cap and spark plug 2 Install a compression gauge in the spark plug hole pull the recoil starter rope several times with force and measure the cylinder compression 10 Cylinder compression 0 45Mpa 800rpm C Ignition system E Fill in oil to the demanded level m Use the genuine spark plug A7RTC RW Spark plug inspection 1 Disassemble spark plug 2 Install spark plug onto spark plug cap 3 Set the oil switch to the ON position Ground the negative electrode i e threaded part of the spark plug against the shroud and pull the recoil starter rope to check the spark plug warning m Dont pull the recoil starter while touching the high tension wire with wet hands High voltage generates which is very dangerous E Drain the gasoline from the fuel tank and carburetor BM Pull the recoil starter several times to release the unborn gas in the cylinder with the engine switch OFF 12 Measure the spark plug gap and perform the spark plug test Standard clearance 0 6 0 8mm Perform the spark test again using a Good spark new spark plug Replace the spark plug No spark Remove the control panel Perform Good spark
28. nd safety equipment When performing maintenance or repairs be especially careful of the following E Read the instructions before you begin and be sure you have the tools and skills required to perform the tasks safely BM Be sure that the engine is off before you begin any maintenance or repairs This will reduce the possibility of several hazards Be careful for carbon monoxide poisoning from engine exhaust Be sure there is adequate ventilation whenever you run the engine Be careful for burns from hot parts Let the engine cool before you touch it Be careful for injury from moving parts BM Do not run the engine unless the instruction tells you to do so Even then keep your hands fingers and clothing away BM To reduce the possibility of a fire or explosion be sure when working around gasoline use only a nonflammable solvent not gasoline to clean parts Keep all cigarettes sparks and flames away from all fuel related parts 2 3 Service rules 1 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 2 Use the special tools designed for the product 3 Install new gaskets O rings etc when reassembling 4 When torque bolts or nuts begin with larger diameter or inner bolts first and tighten to the specified torque diagonally unless a particular sequence is specified 5 Clean parts in cleaning solvent upon disassembly
29. ng into cylinder with piston top and measure the piston end clearance Standard mm Service limit mm 0 15 0 25 1 0 64 Piston ring height Standard mm Service limit mm The 1 ring 0 97 0 99 0 87 The 2 ring 1 17 1 19 1 107 Piston pin outer diameter Standard mm Service limit mm 12 994 13 000 12 950 Piston pin hole inner diameter Standard mm Service limit mm 13 002 13 008 13 050 AN 65 Clearance between piston pin and piston pin hole Standard mm 0 002 0 014 Service limit mm 0 080 Connection rod small end inner diameter Standard mm Service limit mm 13 006 13 017 13 080 B eo Li KS Z Ai Wry Connection rod big end inner diameter Standard mm Service limit mm 24 020 24 033 24 090 Crankshaft neck outer diameter Standard mm Service limit mm 23 967 23 980 23 900 66 NS 67 Connection rod big end side clearance Standard mm Service limit mm 0 1 0 4 0 8 Oil film clearance of connection rod big end 1 Wipe off the oil on the surface of crankshaft neck 2 Set the plastic wire feeler at the crankshaft neck and install the connection rod Tighten the bolt to the prescribed torque pay attention that don t revolve the crankshaft The tighten torque is 8 t
30. ng outer hook inside the reel groove Spring Starter reel 2 Smear lubrication grease on the starter outer shell claw install the starter reel Revolve the reel anticlockwise to hang the spring inner hook on the starter outer shell claw Starter reel Starter outer shell 3 Make a 8 knot at one end of the rope pass the other end through the reel hole Wind the reel anticlockwise 4 turns to fix the reel 46 4 Pull out rope thrum from starter outer shell hole completely pass it through the handle and make a 8 knot then turn off handle cover Loosen the reel to rebound the spring take care not to allow the reel pop out 5 Install the starter pallet and fix it with bolts a Pallet be Spring cap ee Pallet guide plate Pa Smear the lubrication grease at the back side i x E Si ec A Tighten bolt S gA ye fs ami Smear screw stop solvent Pallet spring Di i Ca SS Friction spring ke Ton 6 Pull the starter for several times and check the ratchet wheel returning 8 3 Inspection 1 Ignition coil Attach the two leads of tester to the primary coil plug of ignition coil and measure the primary resistance of the ignition coil Primary resistance 0 8 1 30 47 Attach one lead of the tester to each terminal of primary coil plugs of ignition coil and the other lead to the spark plug cap then measure the secondary resistance of the ignition coil Secondary resi
31. o 10N m 3 Disassemble the connection rod measure the plastic wire feeler thickness 4 Replace the connection rod if the clearance exceeds the service limit and measure the clearance again Grind the crankshaft neck if the new clearance still exceeds the service limit and use the connection rod less than the standard valve Standard mm Service limit mm 0 040 0 066 0 120 68 Bearing vibration Clear the bearing and dry it check the clearance between crankshaft journal and connecting rod big end by revolving bearing by hands Replace for a new bearing if there is abnormal noise or vibration 69
32. re harnesses securely so that they do not interfere with the rotating parts moving parts and the hot parts 8 Route and connect the wire harnesses properly Be sure that the harnesses are not slack twisted or pulled taut 9 Route the wire harnesses properly so that they do not contact with the shape edges and corners and the end of the bolts and screws on the body 10 If a wire harness contacts the end of the bolts screws or sharp edges and corners protect the contact part of the harness with a tube or by winding with an electrician s insulating tape If the wire harness has a grommet set the grommet securely 11 Take care not to pinch the wire harnesses during installation of a part If a wire harness has the damaged insulation repair by winding with the electrician s insulating tape 12 Read the tester manufacture s operation instructions carefully before operation with tester Follow the instructions of the Service Manual Be sure that the battery built in a tester is fully charged and check the meter before inspection using the tester 2 4 Serial number location The engine serial number is stamped at the underside of engine side cover Refer to these numbers when ordering or making technical inquiries Serial number Engine serial number 2 5 Maintenance standards Engine Part Item Standard mm Service limit Engine Maximum speed without load Cylinder 58 105 ra 57 85 13 05 Pistonpin OD 12 9940
33. sembly ea O Sg E Check the conical face for PESO SE damage and carbon deposits ae DE d H i before installation Connection rod cover j e IW Di si Di x il A Di Don t mix the inlet or exhaust E Connection rod bolt o valve M5X0 8X25 8 10N m Conical face diameter Inlet valve 272 Exhaust valve 20 60 12 2 Piston Manufactory label G d S SES Lu Lu a S l f x i Se S k Kee iii 5 Ze seg 2 24 te x Be E AS N X H a H Tay e E i d The 1st ring i i oak 4 dd E F ARRA vara tae v N ic LALA PRE e ol baa wan Eas Kat y ll La gt Bei A aj i Es Ir The 2nd ring d d d s i A 1 i ap Nid WV Ta A I Si AAT EE eng Sie ER E Oil ring il l d A 7 S n i d i Ro S K ee CS eg N i DE Pa I x i IL R i to Piston H j i en DEI E SE j k B Piston pin clip ring Assembly Piston pin set the front end in the piston groove clamp the other end with sharp nose pliers Install the ring clip by revolving it pay attention that the opening should not face the gap of piston pin hole Connection rod _ Assembly PISA Clip ring Assembly of piston ring Caution Set the manufactory label upwards Pay attention not to mix the location of the 18 Install the piston with the connection rod big end points to the right side of piston A label ring an
34. stance 15 21kO 2 Rectifier Measure the on or off positive pressure fall of rectifier with control potentiometer kk the measurement should accord with the standard as shown in the chart 1 Negative pin 2 AC pin N d H th 4 AC pin 3 Positive pin 48 9 Generator Trigger 9 1 Generator Disassembly Reassembly Semicircular key Installation Motor rotor check the installation don t miss anything Installation remove oil and dirty from the E SARI tapered part before installationi Motor stator l Flywheel nut M12X1 25 70 80 N m Impeller Impeller pressure plate 3 Pulse coil Starting pull wheel Trigger Motor sealing coil 9 2 Inspection 1 Ignition winding Measure the resistance between the green terminal and yellow green terminal Resistance 0 40 0 550 2 Outer charging winding Measure the resistance between the two blue terminals Resistance 0 12 0 150 3 Sub winding Measure the resistance between the two sub winding terminals IG series CG series Resistance 0 White White Black White 0 15 0 30 4 Main winding Measure the resistance among the main winding terminals Resist IG series CG series GIS Black Yellow Black Gree Q Black Black Black 0 ey ee n Black Red 120V 230 240V 120V 230 240V 49
35. sti n chamber Check the piston piston ring Norma and cylinder for damage Perform the throttle control system test g Throttle control system test 1 Engine speed too high or too low Abnormal Perform the generator Check the AC output roubleshooting following the instruction of No or low AC output Norma Abnormal Check the throttle contro motor Replace the throttle control motor Norma Replace the inverter unit 15 2 Smart system doesn t work with zero load engine speed doesn t increase with Smart system on and load connected Perform the enerator Abnormal H Check the AC output roubleshooting following the instruction of No or low AC output Normal Abnormal Check the throttle control motor Replace the throttle control motor Normal Abnormal Check the Smart switch Replace the smart switch Normal Abnormal Check Smart switch connection wire Snemma Repair or replace the wire harness Normal Replace the inverter unit h No or low AC output i S ON Disconnect the load and restart the Is the overload indicator light ON engine ore Is the engine speed normal Abnormal Smart switch Perform the throttle control system ON 3200 100rpm est OFF 4300 100rpm Norma Stop the engine and check the AC Abnormal receptacle Replace the AC receptacle Normal Disconnect the 6P connector on inverter unit pull the recoil starter with force and measure the AC voltage between the
36. t DC 100W Rated voltage AC 290 12v zov Rated current AC 7 0A 13 3A 6 7A Voltage variation rate Momentary 10 max Average 1 5 max Average time 3 sec max Frequency variation rate Momentary 1 max Average 1 max Average time 1 sec max 1 3 PERFORMANCE CURVES The curves show performance of the generator under average condition 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 AC External characteristic curves NEEN E DA Kate e 120 a gt i output i ll voltage ai idee dp he ER 8 SEI i nl Rata nn 110 RE dii Dudes ra STR Current A 3 6 9 12 15 VE de AC 230 F EE SE output voltage e SE se V SR gt Current A 0 2 4 6 8 AC 240 EE S EE 2a CA output Alia 8 nia SIE RI voltage V 2 3 0 rr e BRA na ER ae C Ka Current A 0 2 4 6 8 DC External characteristic curves e lina i Seege 24 AN EE x n 22 z ce BE di output 16 voltage vanes V EE SE e WE e gt ae ESA Current A 0 2 4 6 8 1 4 DIMENSIONAL DRAWING Unit mm a 1IG2000 1G2000p CG2000
37. t is normal 22 3 4 Air cleaner Inspection Cleaning 1 Loosen the cover screw and remove the maintenance cover 2 Disengage the locking tab by pushing it and remove the air cleaner cover 3 Remove the element from the air cleaner case 4 Clean the element in warm soapy water rinse and allow to dry thoroughly or clean with a high flash point solvent and allow to dry Dip the element in clean engine oil and squeeze out all the excess oil Excess oil will restrict air flow through the foam element and may smoke at the engine start 5 Install the air cleaner element in the air cleaner case Clean the air cleaner rubber and the air cleaner case if necessary Be sure that the air cleaner cover seals are set securely 6 Install the air cleaner cover Be sure that the air cleaner cover seals are set securely 7 Install the maintenance cover securely Fine element Air cleaner cover Fixed bolt Wash Dry Dip in engine oil Squeeze firmly Sponge sealing strip ni i er i Caution BM A dirty air cleaner will restrict air flow to the carburetor reducing engine performance If the engine is operated in dusty areas clean the air cleaner more often than specified in the Maintenance Schedule m Never run the engine in case there is no element or the filter is damaged as it will do great harm to the engine 3 5 Spark plug Inspection Cleaning 1 Remove the spark plug cap and remove the spark plug 2
38. the same model It can t be used for 3 or more than 3 generators E Only KIPOR parallel output cable and communication wire is allowed to use never try other cables Use the receptacle output of parallel cable don t use the receptacle of control panel m Don t disconnect the PARALLEL I O special communication wire and parallel output cable during parallel operation Connect the PARALLEL I O communication wire and parallel output cable before starting engine Don t disconnect the PARALLEL I O communication wire and parallel output cable until stop operation 18 BM Don t output current after stopping one generator when the parallel cable is still connected BM Do disconnect the parallel output cable and parallel communication wire if operate the generator separately Check whether the two generators could Abnormal Perform single generator ork well separately roubleshooting Normal Is one of the over load indicating light Off 1 Check the parallel output cable on 2 Check the parallel output terminal Jon Check the paralleled I O communication Abnormal Replace the parallel UO ire communication wire Normal Check the paralleled UO communication Abnormal Replace the parallel I O receptacle ommunication receptacle Normal Replace the inverter unit 19 3 Maintenance 3 1 Maintenance schedule Regular service period 1 2 P LU First Every 3 Every 6 Every Item perform at every indicated Each use mont
39. uel switch and fuel filter forl Blocked Clear the fuel switch and fuel blockage filter Ju blocked Hocked No blocked Check the fuel switch and fuel filter Ton Blocked Ju blocked Check sealing of inlet papery gasket and Abnormal Screw the nut or replace the carburetor heat insulation block papery gasket Normal 1 Check the valve clearance 2 Check the carbon deposit in Measure the cylinder compression betel combustion chamber 3 Check the piston piston ring and cylinder for damage Normal Abnormal Check the trigger clearance Readjust the trigger clearance Normal Perform the throttle control system test 14 f Engine speed can t increase or instable choke is at the correct position Blocked Check the air filter element for blockage Clear the air filter element No blocked Check the valve clearance Normal Remove the spark plug and check the electrode clearance for carbon deposit Normal Abnormal Readjust the valve clearance Abnormal Clear electrode adjust clearance lor replace the spark plug Disassemble and clear Screw the nut and replace the papery gasket or heat insulation block and nozzle for Blocked No blockage Abnormal Check sealing of inlet line papery gasket and carburetor heat insulation block Normal SE 1 Check the valve clearance M th lind Abnormal 2 Check the carbon deposit in easure the cylinder compression Smb
40. xhaust valve Revolve direction 25 Caution BM Ifthe inlet valve is on turn the rotor again to align the timing line with the cylinder head seal and both the inlet and exhaust valve should be closed 4 Insert a feeler gauge between the rocker arm and the valve and measure the valve clearance IN 0 10 0 02mm EX 0 15 0 02mm Valve clearance 5 If adjustment is necessary proceed as follows a Loosen the adjusting screw lock nut and adjust the valve clearance by turning the adjusting screw in or out b Secure the adjusting screw with a socket wrench and tighten the lock nut to the specified torque c After tightening the lock nut check the valve clearance again ot Me Dae SI KE Oe d iS Feeler gauge 6 Clean the liquid gasket of the cylinder block and cylinder head cover Apply the liquid gasket Three Bond 1207B or equivalent to the cylinder block installation surface as shown Cylinder seat The liquid gasket 1 5 2 0mm in diameter IT TE K CELE CI N 7 Install the removed parts in the reverse order of removal 26 3 7 Fuel tank Fuel filter Caution BM Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Keep heat sparks and flame away Wipe up spills immediately Cleaning 1 Drain the fuel from the tank and carburetor and then remove the following parts Rear cover
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