IG6000(H) Service Manual
Contents
1. h Low AC output Is the overload indicator light ON Loff Is the engine speed normal Smart switch operation On 2500 100rpm Off 3600 100rpm normal Stop engine and check the AC receptacle normal Vv Check the AC output connector normal Check voltage selector switch only for double voltage selector output abnormal Readjust the clearance abnormal abnormal Perform the generator troubleshooting flowing the instruction of No or Low AC output Replace the stepping motor smart throttle is on and load is increased abnormal abnormal abnormal abnormal on abnormal abnormal abnormal abnormal 16 Perform the generator troubleshooting flowing the instruction of No or Low AC output Replace the stepping motor Replace the smart throttle switch Repair or replace the wire harness Disconnect the load and restart the engine Perform the throttle control system troubleshooting Replace the receptacle Replace the connector Replace selector switch Disconnect the two 6P input connectors on the inverter unit 6p for single voltage 4p or 2p for double voltage Disconnect spark plug cap or igniter connector measure the AC voltage of stator motor is running Measure one AC voltage of main winding or sub2. 16 000 16 018 16 050 50
3. 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 Ignition voltage AC 27 32V Yellow Green No Orange Grey Green Yellow Green M Di i G ee cu 33 7 FRAME HOUSING and FUEL TANK 7 1 Disassembly and reassembly IG6000 Cabinet weldment Glass of float window Cabinet door weldment Sheath of fuel Oil dipstick tank inlet Assembly Fuel tank Check if the float rotating apacity smoothly before assembly Fuel strainer Reassembly Check if the mesh is blocked or damage before assembly Reassembly Check if fuel filter element is blocked or damaged and 1 clean filter element and fuel switch before intalling Fuel feeding pipe Reassembly Check if there is repture and aging before installing Replace every two years NO Control panel Front cover Fixed strap for storage batte Rubber sleeve of handle Battery Battery shim plate Fuel outlet stopper plug i BS X Damping cushion a Reassembly Chassis assembly Check if the damping Lock n E cushion is aging or rupture arth wheel before assembly Gasket Inverter unit Charging regulator Module fixing plate 34 7 2 1G6000h handle assembly Tightening
4. 2 air intake pi COR Cylinder cover assembly Assembly Clean the carbon in buming room and check the status of value basis before installing Locating pin of Wi cover Assembly Check for any worn or aging before installing Air outlet Assembly Check cone for damage and carbon before installing er cover ex Valve guiding pipe a af C ay Air intake Assembly Don t mix with air outlet Cone diameter Air intake 933 Air outlet ev gt Oy air intakde Oil seal of A t Rocker shaft Push rod valve guide Rocker a of valve 8 10 N m Assembly Assembly Rocker shaft bolt Check push rod for 20 23 N m worn and straight before installing 40 heck oil seal for worn before installing Bolt of air intake pipe 9 2 Inspection e Valve spring length Standard mm Service limit mm 39 37 5 eValve seat width Standard mm Service limit mm 0 8 1 2 2 0 eCylinder 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 Service limit If exceed 0 1mm please replace ESI F 4 amp SS gt Inspection section WOR Yd Pes Feeler gauge x ZZ 3 LAr eExternal diameter of valve rod Standard mm Service limit mm
5. Air intake 6 570 5 48 6 50 Air outlet 6 55 6 57 6 50 41 elnner diameter of valve guiding pipe Standard mm Service limit mm Air intake outlet 6 600 6 622 6 68 eClearance between valve rod and valve guiding pipe Standard mm Service limit mm Air intake 0 015 0 052 0 11 Air outlet 0 030 0 072 0 13 42 10 CRANKCASE COVER CAMSHAFT PISTON and CONNECTING ROD 10 1 Disassembly and reassembly a Crankcase cover Gasket of crankcase cover ocating pin of cran jcase cover Oil gauge d Gasket of oil gauge L 5 A M 1 f AM bs Ss Q ml l Nu Se e A Ball beraring b Crankshaft camshaft and piston Piston Assembly Push the v mark at the top of piston towards to pahing rod before installing X Valve tappet Y Assembly Oil seal Joy Prevent loosening when LA ay install valve tappet then zz install camshaft immediately f 2 NN e Camshaft Assembly Check for damage and fatigue of spring and the flexibility of pressure reducing counter weight before install Counter weight Main body Ball b aring Low oil alarm a Don t bump oil seal CE i Connectiong rod cover when install push it until bolt M8 20 22 N m Assembly contacting with the bearing Face the cil throwing needle to camshaft install after bottom basis collimating the raised p
6. Infinity 2 Continuity Infinity Infinity 31 3 Continuity Continuity Continuity 4 Continuity Infinity Infinity 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 The indicated current cannot exceed 1 5A If there is no current present replace the regulator e Make sure the AC input voltage of charger is normal when check the charging regulator e Check the Cathode connection current of battery with DC meter when the battery wire is connected DC charging 13 14V voltage DC charging lt 1 5A current AC Input blue Shell grounding Output positive pole red c 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 7 12 seconds then the output should drop to 0 volts e Connect the sufficient battery before inspecting On line measurement can not be disconnected to the connectors e Measure after the engine stopped more than one minute 32 Yellow Green White IR Sd A E w Red Blue a Black Black SN c coll CB pM a IRI
7. alarm inspection 1 Disconnect the orange oil alarm wire when the engine stops and ground the terminal specified in the diagram and confirm that the alarm light is on and the engine stops or won t restart Outlet terminal of ignitor Outlet terminal of oil alarm Ground through engine cover 20 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 Outlet terminal of ignitor 3 Drain all the engine oil in the engine repeat the test The switch is working properly if there is normal conductivity 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 A Attention eExcess oil will restrict air flow through the foam filter core and may smoke at the engine start Cover of ail cleaner Clean Twist to dry Dip into oil Squeeze out the excess oil aye g aye SO Sar a Wi 21 4 Install the air cleaner element in the air cleaner case close cabinet door A Attention mDirty air filter will affect the air into the carburetor and reduce the engine work pow
8. before installing and checking 13 Measure the spark plug gap and perform the spark test Standard gap 028 034 in 0 7 0 8 mm voltage cable and insulation cap Check or replace wiring harness d Engine oil level is low but engine does not stop Drain out all engine oil disconnect the low oil alarm wire and check if the outlet terminal is connected to ground not conductive conductive Connect the alarm wire loosen ignition module receptacle and check if the orange wire is connected with the ground not conductive conductive Replace ignition module e Engine speed does not increase or is unstable Check air filter element for clog not clogged Check the valve clearance normal Remove the spark plug and check the electrodes for carbon and spark plug gap clogged abnormal abnormal 14 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 spark no spark Disconnect low oil alarm and perform the Replace low oil alarm spark test sag norma no spark Check the ignition control module Replace the ignition module normal Check resistance of motor ignition winding abnormal Replace the motor
9. 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 Smart Throttle Switch The switch is conductive when ON and not conductive when OFP Ignition Module Remove the 10P connector from the module and connect one meter lead to the cover and the other lead to the 10P connector and measure resistance 30 Color of wire Circuit unit Stipulated resistance Blue Primary coil of the ignition coil 0 8 1 30 Orange Low oil alarm No continuity under normal oil level Yellow Coil of trigger head 80 1300 Yellow Green ground Continuity Green Power coil winding of module 0 37 0 410 Red Engine stop switch Continuity when OFF and no continuity when ON Ignition Switch Blue Orange Yellow Yellow green Green Red Check for continuity of each group of contacts with the switch in the off on and start positions DEAE E DE E T OFF e e e e T mu uium mum B ON e e n START e e 5 1 Bridge Rectifier Measure the positive voltage drop of each leading feet of rectifier bridge with the diode checking gt F function of the meter and the result should be compatible with the following standard Tester 1 2 3 4 Tester 1 Infinity Infinity
10. moving parts e Donotrun the engine unless the instructions tell you to do so Keep your hands and clothing away from rotating parts e To reduce the possibility of fire or explosion exercise extreme caution when working around gasoline Use only a nonflammable solvent not gasoline to clean parts Keep cigarettes sparks and flames away from all fuel related parts 2 3 Service Rules e 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 e Use special tools designed for the product when specified e Always install new gaskets O rings etc when reassembling components e When tighten the bolt or nut please from major diameter to minor diameter from inside to outside Tighten the bolt and nut to the specific torque in this way e Clean parts in cleaning solvent upon disassembly Lubricate any sliding surfaces before reassembly e After reassembly check all parts for proper installation and operation e 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 e Use only metric tools when servicing this engine Metric bolts nuts and screws are not interchangeable with non metric fasteners The use of incorrect tools and fasteners will damage the engine e Be sure to follow the mark and instruction of t
11. rotor normal Check trigger air gap and trigger Adjust the air gap and or replace the trigger abnormal resistance normal Check the ignition coil resistance and high Check the ignition coil abnormal Replace the oil level alarm switch Repair or replace wiring harness Clean air filter element Adjust the valve clearance Clean the spark plug and adjust the spark plug gap or replace new spark plug normal Check each carburetor hole and main nozzle for blockage not clogged Check the air intake paper gasket and the sealing of heat insulation block of carburetor normal Test the cylinder compression normal Perform the throttle control system troubleshooting clogged abnormal abnormal Disassemble and clean Tighten the nuts securely replace the gasket or heat insulation block 1 Check the valve clearance 2 Check combustion chamber for excess carbon 3 Check the piston piston ring and cylinder for wear and damage f Engine stops after starting the smart throttle is in proper position Check the engine oil level and check if oil level alarm activates when rotation stops sufficient oil Check the fuel in fuel tank sufficient fuel Check for operation of fuel switch and blockage in fuel filter not clogged Check for blockage of fuel hoses no
12. screw Sliding sleeve Handle spring S vi Hapdrail support p andrail support T Js Stand bar Z Kickstand Lock Land wheel 7 3 Vaporize control system Fuel tank cap assebly Fuel tank cap Inner threaded Inner pallet of of fuel tank cap fuel tank cap of fuel tank cap Fuel filler strainer Material and certificate number X6800BM Q 08 006 Fixed mount weldment of arbon jar Negative pipe of carbon jar connecting air filter 35 8 ALTERNATOR IGNITION COIL 8 1 Component Identification a Disassembly and assembly Seal ring for cylinder Tightening bolt for cylinder cover ff Jt Gaskel Disassembly SN pw Cylinder top sheath cylinder shading Remove cylinder shading frst oe TRIGGER FAN COVER Air board Disassembly Remove motor first M s E Electric start 7 motor ue Oylinder TS 36 8 2 Ignition coil and trigger a Disassembly and reassembly b Inspection 1 Ignition coil e Insert each meter pen between the primary coil plug in of ignition coil to measure primary resistance of ignition coil Primary resistance value e Insert one ohmmeter lead to anyone primary coil plug in of ignition coil and the other meter pen to spark plug cap to measure secondary resistance of the igniti
13. to put the engine on a flat floor when checking 1 Remove the oil dipstick and check the level RN P d Q2 Lower limit Screw the oil stick tightly Then unscrew it 2 If the oil level is low add to the edge of the oil filler port upper limit 19 e 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 X Recommended engine oil SE SF engine oil classified by API or SAE10W 30 engine oil which same as SG grade Use SAE10W 30 engine oil when the temperature is below 10 C Use SE or SAE5W 30 engine oil which same as SG grade when the temperature is below 15 C Select the appropriate viscosity for the average temperature in your area 4 Check the oil level after refilling Add the oil to the limit level 5 Tighten the dipstick e Drain the used oil while the engine is warm Warm oil drains quickly and completely e 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 el D v 2 qp i1 3 3 Low Oil
14. 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 A Warning 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 Some of the most important precautions are stated below But we could not list all the potential danger you should judge yourself if it need to do the maintenance task _A Warning Could not follow the maintenance instruction and safety precautions can cause an unsafe condition that can lead to serious injury or death Follow the procedures and precautions in this shop manual carefully 2 2 Safety Precautions Be sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and 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 e Besure that the engine is off before you begin any maintenance or repairs This will reduce the possibility of several hazards Carbon monoxide poisoning from engine exhaust Run engine in the ventilated place whenever Burns from hot parts Touch the engine parts after it cooled Injury from
15. 015 36 025 36 090 48 e External diameter of crankshaft journal Standard mm Service limit mm 25 960 35 975 35 900 e Clearance of side face of big terminal of the connecting rod Standard mm Service limit mm 1 05 1 25 1 5 eClearance of oil film of big terminal of connecting rod 1 Remove the engine oil on the surface of crankshaft journal 2 Set plastic line gauge on the crankshaft journal and install the connecting rod Tighten the bolt according to stipulate torque Pay attention not to rotate the crankshaft when tightening Tightening torque 14 16N m 3 Remove the connecting rod and measure the thickness of plastic line gauge 4 If clearance exceeds service limit please replace the connecting rod and then measure the clearance again If the clearance still exceeds service limit after changing a new rod please polish the crankshaft journal and use the connecting rod that is less than standard value Standard mm Service limit mm 0 046 0 060 0 120 Plastic line gauge 49 e Height of camshaft Standard mm Service limit mm Air intake 32 60 32 80 32 25 Air outlet 32 09 32 29 31 75 eExternal diameter of camshaft Standard mm Service limit mm 15 966 15 98 15 92 elnner diameter of bearing of camshaft Standard mm Service limit mm
16. 12 0 160 4 Sub winding coil Measure the resistance between two white wires or green depending on the date of manufacture Resistance value 0 08 0 120 Measure the resistance between three wires in black or red 5 Main winding 120 240V Resistance value Double voltage 120V 240V Single voltage 0 45 0 600 0 09 0 100 0 9 1 10 39 9 CYLINDER COVER and VALVE 9 1 Disassembly and reassembly Cylinder cover bolt M10X1 25X80 42 46 N m Assembly Tighten or loosen the bolt crossedly Do the tightening equably and ordering until to specified torque Cylinder cover Exhaust pipe bolt Cylinder cover D T E D an S d a mi J gt Vent pipe Gasket of cylinder cover Assembly Check for any worn or aging before installing Assembly Check for any worn or aging before installing Air outlet spring seat Disassembly Press lightly the spri ng basis and remove it towards to t e neighboring hole E Spark plug Assembly i CD Don t mix it with the spring yy basis of valve Double screw 2D Cylind Mu r bolt AM8X20 yn Air inlet Air outlet spring seat spring seat Cr f Low seat of valve spring Q Uh s Adjusting cushion valve sping 5 n of air outle ee only for air outlet v Guide plate of push rad EXE Rocker arm of valve Gasket of pring seat o m Nt Ix EN A
17. IKIr Or WUXI KIPOR POWER CO LTD IG6000 IG6000h Generator Service Manual Kipor Power Systems August 1 2011 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 All information illustrations directions and specifications included in this publication are based on the latest product information available at the time of printing KIPOR POWER CO LTD reserves the right to make changes without incurring any obligation whatever No part of this publication can be reproduced without written permission TABLE of CONTENTS TS SPS CIIGATONS LS 4 1 General Specifications enini eese Ie cee Pese sos resp pee te pele eds seda REP Cepeda ce rene Rech 1 2 Generator Specifications sssssssseseseeeeeeeeeeeeeeene nennen rennen nnennnnnnh nnne nnne nn n nnne nnn 1 3 Performance Curves nennen nnne nnnnn ener sinn EEEE EEEE EEEE sien eser eser sse sinas in EERE HESS 1 4 Dimensional drawings itii die rit dere et erbe ie te eee ees Eod lente e Ee et bes edes teda 1 5 Wiring DIagratm ce eere hector delete pentru ge arece ne ner sete e PATOSE Maat ei Sede 2 Service and Maintenance sssssssssssssssssses
18. Ulffle os s nor e tur ove edt tA aR ath en eom er mr ON LH ethan eee 4 3 Air vent pipe and second gulp valve sssssssssse b Carburetor imde ite dette eod RE eee E RES 5 1 Disassembly and Reassembly sssssssssssssssssssseeeesee nennen nennen nenr nenne nenne nenne 5 2 lnspectlori pec f Per id err e bp fusi eeu b bebo erg tes Los eda BOR E ud 6 Control Panel charging adjustor timing relay Ignition control module inverter Module 6 1 Disassembly and Reassembly ssssssssssssssssssseeeeee eene enne nennen seen enne 6 2 INSPOCHION 22 428 fetes dtt ta tbe muet tibt ERE 7 Housing group and Fuel Tank ssssssssssssssssseseseeeeeeeee eene nne nen nennen nnn nennen nnns 7 1 Disassembly and Reassembly IG6000 ssssssssssssssssseeeneeeenenmenenne nennen 7 2 Disassembly and Reassembly IG6000h sssssssssss eene 7 3 Vaporize control system sssssssssssssssssssesessese eee nemen serene 8 Alternator Ignition Coil Trigger electric motor air guide cover sssssesseeeenee 8 1 Air guide cover cylinder end cover cylinder bottom cover air guide plate electric motor 8 2 Ignition Coil and Trigger eR DEO REOR ERE EE A eaae aa RR ER RR AR EEER pate O 9Alteriatolo d ess eMe iioi ues Lot Me hte Nees eu LM RA TAN CR Rr FARE E See OM aetna Aco ano 9 Cylinder cover valve ss
19. Winding for double voltage unit Black black 30V White white 1V Single voltage230 240V type Black black 60V White white 1V Single voltage 120V type Black black 30V White white 1V main winding and sub Winding when the normal 255 volts Replace inverter unit i No AC output Is the engine speed normal normal Check AC receptacles normal Check the rectifier normal Measure the resistance between two blue wire on the rectifier Resistance 0 03 0 040 normal Rotor losses excitation replace the rotor j Electric starter doesn t run Check the battery voltage normal Check ignition switch normal Check the battery switch normal Vv Check the starting motor normal Check and repair or replace main wire harness abnormal abnormal abnormal abnormal abnormal abnormal abnormal abnormal abnormal 17 1 Check the wiring of the stator leads in the harness Repair or replace the harness 2 Rotor internal magnetic weaken replace the rotor Perform the throttle control system troubleshooting Replace receptacles2 7 9 Replace the rectifier Check and repair the wire harness or replace the stator Replace the battery Replace the ignition switch Rep
20. art of connecting bar and cover 43 eAlignment of time setting marks Align camshaft with comparison marks of time setting gear small gear on camshaft before installing Comparison mark M N gear IL c Piston and connecting rod Manufacturer mark Manufacturer Assembly Put the front part on the piston grave and clamp the other end with nipp plier then rotate and install it in the groove Don t let opening of snap ring face to gap piston Snap ring 44 Assemble of piston ring Caution e Put the manufacturer mark facing up when installation e Pay attention to the installation positions of 1 and 2 ring e Check if the piston ring can rotate freely after installing e All openings of piston ring should be kept away from the direction of piston pin with 120 degree angle P ic ring chromeplated 2nd ring surface phosphorized zx id Cil ring Li 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 using instrument 2 Convert the low oil alarm and measure again it should be not conductive 3 Dip the low oil alarm into engine oil in order to inspect float and measure again it should be not conductive Copper grounding piece eNoise and moving of shaft Clean and dry the shaft rotate the shaft manually and check the free gap if any noise or moving replace the shaft Free
21. e stop station 3 Insert a feeler gauge between the rocker arm and the valve and measure the valve clearance intake 0 06 0 02 mm Valve clearance exhaust 0 08 0 02 mm 4 If adjustment is necessary proceed as follows a lock the rocker lever adjustment screw and loosen the nut b move the rocker lever adjustment screw until the correct clearance is achieved c tighten the nut on the rocker arm adjustment screw d recheck the clearance after adjustment 23 3 7 Fuel switch and fuel filter cleaning Fuel tank s Sealing gasket Filter core or element Fuel switch A Attention E Keep smoking materials and any open flames away during fuel system maintenance B6 Make sure that there is no leaking fuel after service 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 the sealing gasket filter core and fasten the connection nut between fuel switch and oil tank 24 4 AIR CLEANER and MUFFLER 4 1 Air cleaner e Disassemble and reassemble e Bottom case of air filter Sealed gasket Filter fixed price damage or deformation Check sealing surfaces on all four sides 1 t ar eta Filter el
22. ed gasoline KD70 Generator type Multi pole rotation type Generator structure Self ventilation drip proof type Excitation Self excitation Magnet type Voltage regulation system Pulse Width Modulation Phase Single phase Rotating direction Clockwise Viewed from the generator Frequency regulation AC DC AC conversion Inverter type 1 2 Generator Specifications Model IG6000 Maximum output AC 6 0 KVA Rated output AC 5 5 KVA Rated frequency HZ 60 Rated voltage AC 120 240 Maximum current amp 50 25 Rated current Camp 45 8 22 9 Rated voltage DC Rated current DC Power factor 12V 1 0 E Momentary Voltage variation Max 10 Average rate Max 1 5 Average time Max 3 seconds Voltage stability 1 Momentary Frequency Max 1 Average Max 1 variation rate Average time Max 1second Frequency stability Insulation resistance 0 1 Min 10MQ AC circuit protector Amps 120 240 VAC DC circuit protector 51 7 25 8 Fuel tank capacity gal L Operating hours at rated load Noise level dB 23 7 m no load full load 1 3 PERFORMANCE CURVES The curves show performance of the generator under average conditions Performance may vary depending upon ambient temperature altitude and humidity eAC External characteri
23. embly Carburetor gasket B L e lit 2d l damage in the gasket before assembly before assembly e Disassembly and installation of stepping motor Stepping motor E A Stepping motor base Fork Fork spring disassembly Hold tight to prevent spring from coming loose Fork spring y Carburetor disassembly and reassembly Fork A Fork sprin S i Assembly of accelerator Ne P Jis SED aiden rod Gland bugh 55 N Air chock piece mor gt e P TL Return spring O Accelerator piage of air choke X Channel block amp kA n CGY D BS Seal ring t 8 4 9 5 Dust cover i D ED D Adjusting screw of SI c the mixture ratio Fixed screw o lex Gasket The position has been set accelerato H SW before leaving factory caburetor body don t adjust the screw Reassembly Inspect the abrasion of First remove the channel dirt with compressed air before installing Attention to the direction of the installation Main nozzle Assembly Clean channels with compressed Seal ring of air before installation Float fuel cup ssembly lt a Check for smooth Oil drain bolt of fuel cup ET movement after installation Assembly Make sure there is no fuel z leakage after installing 4 Oil ring Magnetic valve seal GX Ti of fuel ighten screw seal of fuel cup REV i Assembly Make sure there is bs e no fuel leaka i ge after locking 1 dd y Ma
24. ement Carburetor gasket 7M Air filter cover Install m ue LEE B Ir Make sure that gaskets have no v i ho f L 4 2 Muffler e Disassembly and assembly Muffler syphon Assembly Clean the carbon inside muffler syphon using the brush before installing Fireproofing cap Assembly Clean the carbon using the brush before instal ling Exhaust pipe gasket Muffler gasket Muffler Assembly Knock it to remove carbon in side by using rubber hammer before installing Cover of muffler 25 4 3 Air outlet pipe second gulp valve assembly Secondary air injection valve Spark Arrestor Muffler body assembly Muffler elbow pipe 26 5 CARBURETOR WARNING M Loosen the gasoline drain bolts before disassembly to drain fuel in the carburetor l Smoking and any source of combustion are strictly forbidden in the process of disassembly 5 1 Disassembly and reassembly Reassembly Check if there is any dam age in the gasket before Check if there is any damage in the insulator Check if there is any LU Air choke r riae bottom case Air intake pipe gasket i weldment Sealed gasket Reassembly Ge 9 Et x Filter fixed price Check if there is any dam v wey P EV ae Filter elementt age in the gasket before EJ ce Qs f i N Air filter cover assembl Carburetor TL Spo i X 3 assem dg g Insulator block of y Carburetor gask i i carburetor lli rn Reass
25. er If the engine works in dirty place please replace the air filter often mDon t operate the generator without the filter element in place or serious engine damage may result 3 5 Spark plug inspection and adjustment 1 Remove the spark plug cap and remove the spark plug with plug sleeve 2 Remove 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 9KQ 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 5 Install the plug and tighten securely after adjustment the specified torque is 20 30 N 22 3 6 Valve clearance adjustment A 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 qo COE ae a ifs 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 A Attention If the spark plug is in the top position and intake valve is in the START position please blow fan blade And let the spark plug in top position while the outlet valve is in th
26. ese sese e eese e esse sse essei e assesses re sanis 2 1 The Importance of Proper Service ccccccec ee ee ee ee escent eee eee e eee eee nets nets ee et eene 2 2 Safety Preca tloris i cd I hee Peds ck a ee dr ata dE ede 2 3 Seice RUGS ais see e eieae tp e to e a e lente oi ces uae eee ms eet ea an cee E 2 4 Serial Number and Bar Code Location cccccceceeeeeee ee ee eee eee eeee eee eeeeeeeeneeeeeeeeeeties 2 5 Engine Service Standardsete leiet annaa E Ea eee e ee eee eee EE EEEE RAA aa A VEENAS 2 0 Fastening TOrqUES no Piden debe S a a ede DE RA FIR RE nd a aiaa ERR 2 7 Troubleshooting irr orte e Eee UI dede va desees ved sgh ov eae epa eur viera ede vadant 3 Inspection and Adjustment ener nnn tennnnente TEFIE AENEA nennen nennen 3 1 Maintenance Schedule ssssssssssssssssssssseeee nennen nennen ener nnne nnn taere nnns nnns rne 3 2 Etngine Oil 33 155 23 0 Etc over lt eot nis etate Cobre SS LOW Ollealanns ME 3 4 Air Cleaner ce i e ex Piva ca e GRO wot I UE He EUN UI TT sake 3 5 Spark Plug efe ctr iat Gitte eis He Oe hai det t ee a Pe tet Ci Pep odd 3 6 Valve Clearance i deret ete err rete euntem Po retten bti e edu qu gap entera det 3 7 Fuel Switch Fuel Ellter x x cet rere ados e eee pa mete ex fette redde eee ee ede ete a esa a 4 Air Cleaner Muffler e e te TI RR eK ERR IRER ENUMERARE RR e px Eae i RES 4T AI Eleanet stt sett ttti tic tx sat f tut ttt e tL e Er as 4 2 M
27. gap Free gap Vertical direction Circular direction 45 e Inner diameter of cylinder Standard mm Service limit mm 88 015 88 035 88 17 e External diameter of the apron of piston Standard mm Service limit mm 87 96 87 98 87 85 e Clearance between piston and cylinder Standard mm Service limit mm 0 045 0 065 0 120 e Side clearance of piston Standard mm Service limit mm 0 045 0 060 0 150 46 e 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 1 0 e Height of piston ring Standard mm Service limit mm The first ring the 1 97 1 99 1 87 second ring e External diameter of piston pin Standard mm Service limit mm 19 994 20 000 19 950 47 e Internal diameter of piston pin hole Standard mm Service limit mm 20 002 20 008 20 050 e Clearance between piston pin and pin hole Standard mm Service limit mm 0 002 0 014 0 080 e Internal diameter of the small terminal of connecting rod Standard mm Service limit mm 20 007 20 020 20 090 e Internal diameter of the large terminal of connecting rod Standard mm Service limit mm 36
28. gnetic valve O O Resistance of magnetic valve is 6 8 o Tighten screw of fuel cup NW NNI 28 5 2 Stepping motor fuel shutoff solenoid eFloater 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 Floater eStepping motor 1 Measure the resistance of outlet terminals of stepping motor 1and3 50 550 2and4 50 550 resistance value Replace the stepping motor if the resistance exceeds the standard 2 Measure the resistance of fuel shutoff valve resistance value 6 80 Replace the throttle electromagnetic valve if the resistance exceeds the standard value 29 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 t Zr gt 4 M S P927 T Module fixing plate 2 zu SIN P ce Inverter unit ye Xa Kk Charging regulator Modulefixing plate1 6 2 Inspection a Control panel AC Receptacle Check for evidence of burning or contact damage Replace if either condition exists DC Receptacle Connect both terminals of the receptacle with a jumper wire and check if the receptacle is conductive with two meter leads
29. he book when use the tools m Electrical Precautions e 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 e Check the connector terminals for bend excessive extrusion missing terminals or other abnormalities before connecting the connector e To connect insert the connector as far as it goes If the connector is a locking type be sure that it is locked securely e Check the connector cover for breakage and check whether the connector female terminal is not opened 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 e Set the harness clips in the specified places of the frame securely and secure the wire harnesses e Clamp the cables securely e Clamp the wire harnesses securely so that they do not interfere with the rotating parts moving parts and hot parts e Route and connect the wire harnesses properly Be sure that the harnesses are not slack twisted or pulled overly taut e Route the wire harnesses properly so that they do not contact sharp edges and corners and the end of the bolts and screws on the body e fawire harness must contact the end of the bolts or screws or sharp edges and corners protect the contact part of the harness with a loom or by winding wi
30. lace battery switch sucking coil Replace the starting motor k The battery doesn t charge Check ignition switch normal Check charging regulator normal Measure resistance of charging coil winding Resistance 0 12 0 160 l Check and repair or replace wire harness abnormal abnormal abnormal 18 Replace ignition switch Replace the charging regulator Check and repair electric wire harness or replace stator 3 INSPECTION AND ADJUSTMENT 3 1 MAINTENANCE SCHEDULE Regular service periodCD Each use Each Every3 Every6 Every year a dan Deae RUE I see month or months months or or every whichever comes first every 10 orevery every 100 300 hours Project hours 50 hours hours Engine Oil Check e Replace e e Air cleaner Check e Replace e 2 Spark plug Clean Adjust e Spark Arrestor Clean e Valve clearance Check Adjust e Fuel tank and filter Clean e Fuel line Check Every 2 years and replace if necessary Note DInterval 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 PLEASE READ KIPOR OPERATION MANUAL 3 2 Engine oil e Checking the oil level Stop the engine and check the oil level be sure
31. le and restart the engine and 2 check cylinder head gasket for leakage check the cylinder compression sis 3 Check combustion chamber for excess carbon buildup cylinder 4 check valve conical surface and valve compression seats 5 check piston piston rings and cylinder for worn normal compression 80 psi 55 Mpa Install the spark plug Restart the engine according to the starting procedure m 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 Cylinder compression 0 55Mpa 600rpm c Ignition system troubleshooting m Fill oil to the specified location before inspecting m Please use the WR7DC spark plug mSpark plug inspection 1 Remove 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 A Warning m Do not pull the recoil starter rope while touching the high tension wire with a wet hand High voltage is generated which is dangerous m Make sure no spilled fuel is anywhere on the engine and no fuel is on the spark plug before testing m Keep sparks and any other combustible source away from the spark plug hole and engine metal case
32. ning Torques Tightening torque Item Specification Kgf m Connecting rod bolt M8 2 0 2 2 Cylinder cover bolt M10x1 25x80 4 2 4 6 Spark plug M14x1 25x19 2 0 3 0 Crankcase side cover M8x30 2 0 2 3 Flywheel nut M18x1 5 12 0 13 0 Rocker arm shaft bolt M8x16 2 0 2 3 Adjusting nut of rocker M6x0 75 0 8 1 0 arm shaft M5 bolt nut 0 5 0 7 M6 bolt nut 0 8 1 0 Standard torque c M8 bolt nut 1 8 2 2 M10 bolt nut 3 5 4 5 Note Use standard torque values for fasteners not listed in this table 11 2 7 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 Fuel filter clogged Clean Fuel hose clogged Clean Fuel switch won t operate Replace Carburetor defective Clean and and adjust Ignition coil defective Spark plug defective Inspect and replace Inspect and replace Engine does not Trigger defective or improper air gap Inspect and replace start or hard starting Oil alarm defective Spark plug cap disconnected Inspect and replace Install securely Ignitor defective Inspect and replace Ignition coil defective Inspect and replace Opening
33. nkshaft Crank pin O D 35 960 35 975 35 90 Valve clearance Intake 0 06 0 02 Exhaust 0 08x0 02 ELIT Valve rod OD Intake 6 570 6 585 6 50 Valve Exhaust 6 550 6 570 6 50 Vessel D Intake Exhaust 6 600 6 622 6 68 Seat width Intake Exhaust 0 8 1 2 2 0 Valve spring Free Length Intake Exhaust 39 37 5 Cam wheel Cam height I D Intake 32 60 32 80 32 25 Exhaust 32 09 32 29 31 75 Camshaft O D 15 984 15 966 15 920 Valve tappet O D 8 96 8 98 8 87 Crankcase Valve tappet ID 9 000 9 015 9 06 Camshaft Bearing LD 16 000 16 018 16 05 Crankcase cover Camshaft Bearing I D 16 000 16 018 16 05 Carburetor Main metering jet 1 02 Floater height 13 Indicating bolt opening 2 ring Spark plug Clearance 0 7 0 8 Ignition coil Resistance Primary side 0 8 1 30 Second side 15 21kO Pulse coil Air gap 020 030 0 5 0 75 Trigger Resistance 80 1300 Carburetor magnet Resistance 6 80 10 Alternator Maintenance Standards Standard Q Type 120V 240V 120V 240V Double voltage Single voltage Orange Ignition winding Resistance Yellow Green Gray orange 0 15 0 17 0 22 0 24 External d Resistance Blue blue 0 03 0 04 charging winding Built in charging vee Resistance Purple Purple 0 12 0 16 winding White whit Sub winding Resistance we 0 08 0 12 green green Black black Main winding Resistance ML ae 0 45 0 60 0 09 0 10 red red 2 6 Faste
34. on coil Secondary resistance 15 21KO value 37 2 Trigger e Insert each meter pen to each trigger outgoing line to measure trigger resistance Trigger head resistance 80 1300 C Adjustment Adjust the clearance between the trigger head and rotor Trigger head clearance 020 029 in 0 50 0 75 mm s SPA 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 38 8 3 Alternator a Disassembly and reassembly Wire pressing board Ux Fs as Ignition coil X Ignition coil bracket P b Inspection 1 Ignition coil Electric motor stator Seal ring for bus line Motor rotor Assembly Remove amp clean off the grease dirty amp when install the rotor Flywheel nut M8x1 5 120 1230N mY Gasket Orange Yellow green 0 22 0 240 Resistance value Gray Orange 0 15 0 170 2 External charging coil Measure the resistance between the two blue wires Resistance value 0 03 0 040 3 Built in charging coil Measure the resistance between the two purple wires Resistance value 0
35. set of smart throttle improper In whole or semi location Timing relay defective Inspect and replace Ignition winding control module defective Inspect and replace Carburetor faulty Clean and adjust Engine speed does not stabilize Inverter unit defective Throttle control stepping motor defective Inspect and replace Inspect and replace b Hard starting or no start Valve clearance misadjusted Readjust Check the fuel level in the tank no fuel Add fuel and restart the engine Sufficient fuel Check fuel switch is in ON position off Turn on it and restart the engine Jon Loosen the drain screw and check Check the timing relay for damage and fuel whether fuel reaches bowl and whether abnormal system for blockage the fuel level is normal normal Remove and check spark plug and check sadi Check each carburetor hole and nozzle for if electrode is wet or dry blockage Clean and dry the carburetor and observe choke action if severe wet check if any fuel wet i leakage and if the floating valve is normal Attach the spark plug on plug cap ground no spark Perform the ignition system troubleshooting 12 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 ho
36. ssseeenn nnne 9 1 Disassembly and Reassembly ssssssssssssssssssseeneee eene nennen nennen nennen nnne nennen 9 2 Inspection 2rd E e et ee PH ER D D a HERR eee elated etna 10 Crankcase cover Crankshaft Camshaft Piston Connecting rod sessesss 10 1 Disassembly and Reassembly ssssssssssssssssseeeseneee eene nnn nennen nennen nnne 10 2 Inspection oe nU etr emere nae nemen rit endet 1 SPECIFICATIONS and DIAGRAMS 1 1 General Specifications Dimensions and weights Model IG6000 Overall length in mm Overall width in mm 31 6 802 19 4 498 Overall height in mm Dry weight Ibs Kg Engine Model 24 6 624 213 96 7 KG390GETi Type 4 stroke OHV single cylinder Displacement cu in cc 23 7 389 Bore x stroke in mm 3 46 x 2 51 88x64 Maximum horsepower KVA 7 7 3600 Compression ratio 8 5 1 Cooling system Forced air Ignition system Transistorized controlled ignition Ignition timing Spark plug 25 B T D C WR7DC Carburetor Horizontal float amp fly type Air cleaner Governor Dry replaceable element Inverter module control Lubrication system Forced splash Oil capacity qt L 1 2 1 1 Starting system Electric starter Stopping system Electric ground Fuel Generator Model Automotive unlead
37. stic curves gt O o c o c S lt o QD Q D S Current A ebeyoA jndjno oy e DC External characteristic curves gJ aah R O a EN 3 4 gej E ES e Reed lt os o saa 5i fx doa D P 2 4 6 8 10 12 1 5 Wiring Diagram a Single voltage output DC receptacle Blue Blue indi Red DC winding Blue Blue eb o ee Rectifier bridge ack o r3 Secondary winding White Inverter cell Red A J Red yams pews Receptacle of single phase p elow Olivine 3 Orange iz a Blue R White A Browne g E Pm 5 Gray c Working indi ator uU Purple Gray Yellow Overload indjcator Black Orange tel th SK Blue C Low oil indicator Purple Guipuim sabu JIMS uue e o MOT eee a Snid yseds lt L joo uous Olivine b Double voltage output Blue Blue DC receptacle DC winding o Blue Black Us Main winding Black B Red T 3 i w Black C White 8 Secondary winding Red Main winding Red Inverter cell Green Secondary winding Green Yellow Jojoui Buiddays Purple a ot oO 2 Charging 9 winding a so Purple iG jio uoniuB Olivine Electromagnet of oil line 2 SERVICE and MAINTENANCE 2 1 The importance of proper servicing Proper servicing is essential
38. t clogged Turn the ignition switch to ON position check the timing relay for output Check each carburetor hole and main nozzle for clogged normal fuel flow of carburetor heat insulation block Check the intake gasket and the sealing normal Measure the cylinder compression oil level alarm no fuel clogged clogged has clogged abnormal abnormal 15 Add oil and restart the engine Add fuel and restart the engine Clean the fuel switch and filter Clean or replace the hoses Replace the timing relay Disassemble and clean Tighten the nuts securely replace the gasket or heat insulation block 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 normal Perform throttle control system troubleshooting g Throttle control system troubleshooting 1 Engine speed is too high or too low Check AC output normal Check the stepping motor normal Replace the inverter unit 2 The engine speed does not increase when Check the AC output normal Check the stepping motor normal Check the smart throttle switch normal Check Smart switch connecting wire normal Vv Replace the inverter unit
39. th electrical insulating tape If the wire harness has a grommet set the grommet securely e 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 e 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 4 Serial Number and Bar Code Location The engine serial number is stamped beside the engine oil drain plug This number is used to identify the specific engine version Engine serial number 2 5 Maintenance standards of engine valve Part Item Standard in mm Service limit Engine Max speed under zero load rpm lt 3780rpm Cylinder pressure 0 55MPa 600rpm Cylinder Cylinder sleeve I D 88 015 88 035 88 17 Piston Piston skirt O D 87 96 87 98 87 85 Vp 20 002 20 008 20 05 Piston pin O D 19 994 20 000 19 95 Height h 1 97 1 99 1 87 Side gap t 0 02 0 06 0 15 First ring second ring Closed gap 0 2 0 35 1 0 Thickness t 3 9 4 1 3 7 Piston ring Height h 2 68 2 75 2 58 Side gap t 0 055 0 14 0 20 Oil ring Closed gap 0 20 0 50 1 0 Thickness t 2 9 3 3 2 8 Small end I D 20 007 20 020 20 09 Connecting rod Big end I D 36 015 36 025 36 09 Cra
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