IG1000 Service Manual - Kipor Power Equipment
Contents
1. 42 10 ALTERNATOR TRIGGER 43 10 1 ALTERNATOR 43 10 2 INSPECTION 43 10 3 TRIGGER ADJUSTMENT 44 11 CYLINDER COVER ROCKER ARM 45 11 1 DISASSEMBLY REASSEMBLY 45 11 2 INSPECTION 46 12 CRANKCASE COVER CAMSHAFT DRIVE CHAIN 47 12 1 DISASSEMBLY 47 12 2 CRANKCASE OIL TRAY ASSEMBLY AND DISASSEMBLY 47 12 3 CRANKSHAFT INSTALLATION 48 12 4 CRANKCASE COVER ASSEMBL2. KIPOR POWER PRODUCTS CO LTD IG1000 SHOP MANUAL EPA CARB CETL Certified Models Kipor Power Systems Inc Revision 4 July 2011 2011 Kipor Power Systems Inc Preface ers the construction function and servicing procedures of the KIPOR IG1000 This manual is applicable to all models certified by the California Air Resources Board CARB and EPA CETL built from December 2008 onward The c of both generators is identical but CARB areful observance of the instructions contained in this manual will result in safe and quality ll information illustrations directions and specifications included in this publication are based on the UXI KIPOR POWER CO LTD reserves the right to make changes without incurring any obligation This manual cov onstruction model fuel systems use certified materials Procure the correct parts applicable to your model Models with production dates of 2011 feature overload reset switches and a parallel version is now available C maintenance and repair work A latest product information available at the time of approval for printing W whatever No part of this publication may be reproduced without written permission ii 2011 Kipor Power Systems Inc CONTENTS 1 SPECIFICATIONS WIRING DIAGRAM
3. 20 4 4 AIR CLEANER 21 4 5 SPARK PLUG 22 4 6 VALVE CLEARANCE 23 4 7 FUEL TANK AND FILTER 25 4 8 FUEL PUMP AND HOSES 27 4 9 SPARK ARRESTOR 28 5 MUFFLER 29 6 AIR FILTER CARBURETOR 28 6 1 AIR FILTER REMOVAL AND INSTALLATION 28 6 2 CARBURETOR REMOVAL AND INSTALLATION 28 6 3 STEPPING MOTOR REMOVAL AND INSTALLATION 29 6 4 CARBURETOR EXPLODED DRAWING
4. 30 6 5 INSPECTION 31 iii 2011 Kipor Power Systems Inc 7 CONTROL PANEL 32 7 1 REMOVAL AND INSTALLATION 33 7 2 INSPECTION 33 8 HOUSING FUEL TANK 35 8 1 HOUSING DISASSEMBLY 35 8 2 FUEL TANK ASSEMBLY 36 9 RECOIL STARTER AIR CONDUCT COVER IGNTION COIL AIR CONDUCT PLATE 37 9 1 DISASSEMBLY AND REASSEMBLY 37 9 2 AIR CONDUCT PLATE 38 9 3 RECOIL STARTER 39 9 4 IGNITION COIL
5. 1 1 1 SPECIFICATIONS 1 1 2 WIRING DIAGRAMS 3 2 SERVICE INFORMATION 6 2 1 THE IMPORTANCE OF PROPER SERVICING 6 2 2 IMPORTANT SAFETY PRECAUTIONS 6 2 3 SERVICE RULES 5 2 4 ELECTRICAL PRECAUTIONS 7 2 5 SERIAL NUMBER AND BARCODE 8 2 6 MAINTENANCE STANDARDS 9 2 7 TORQUE VALUES 10 3 TROUBLESHOOTING 11 3 1 GENERAL SYMPTOMS AND CAUSES
6. 11 3 2 HARD STARTING 12 3 3 OIL LEVEL SWITCH 15 3 4 ENGINE STOPS RUNNING 15 3 5 ENGINE SPEED UNSTABLE 16 3 6 ENGINE SPEED TOO HIGH OR LOW 16 3 7 SMART THROTTLE 17 3 8 LOW OR NO AC OUTPUT 17 3 9 NO DC OUTPUT 17 4 MAINTENANCE 19 4 1 MAINTENANCE SCHEDULE 19 4 2 ENGINE OIL 20 4 3 CHECKING THE LOW OIL ALARM
7. 32 Choke valve Fork Fork spring Choke plate Idle adjusting cap Fixed Carburetor block Idle mixture screw fixed Carburetor drain bolt Needle seat Float pin Seal ring of oil cup Oil control needle spring Bowl Oil control needle Foam tube Main jet Float Sealing ring Bowl bolt 2011 Kipor Power Systems Inc 6 5 Inspection Float height Place the carburetor as the picture shows measure the float height between float and carburetor block Height 0 0047 in 12mm Replace the carburetor if the float height is not the right size Stepping motor Measure the resistance of stepping motor lead out wire Standard resistance Between 1and 3 45 55 Between 2 and 4 45 55 Replace the stepping motor if the resistance excesses the above
8. Clean or replace carburetor Blocked Check the carburetor nozzles for blockage No blocked Blocked Clear the fuel switch and fuel filter Not blocked Check seal between inlet gasket and carburetor heat insulation block Normal Measure the cylinder compression 1 Check the valve clearance 2 Check the carbon deposit in combustion chamber 3 Check the piston piston ring and cylinder for damage Abnormal Tighten nuts and or replace gasket Abnormal Normal Check the trigger clearance Abnormal Normal Perform the throttle control system test Readjust the trigger clearance 15 2011 Kipor Power Systems Inc 3 5 Engine speed can t increase or unstable choke is at the correct position 16 3 6 Engine speed too high or too low Check the air filter element for blockage Clear the air filter element No blocked Blocked Check the valve clearance Readjust the valve clearance Abnormal Normal Remove the spark plug and check the electrode clearance for carbon deposit Clear electrode adjust clearance or replace the spark plug Abnormal Normal Check the carburetor and nozzle for blockage Disassemble and clear Blocked No blockage Screw the nut and replace the papery gasket or heat insulation block Check sealing of inlet line papery gasket and carburetor heat insulation block Abnormal Normal 1 Check the v
9. Engine Model KG144 Type 4 stroke OHV single cylinder Gasoline engine Displacement cu in cc 3 3 53 5 Maximum horsepower rpm 1 3 5500 Compression ratio 8 5 1 Cooling system Forced air cooled Ignition system T C I Ignition timing 29 B T D C Spark plug UR5 Carburetor Float type Horizontal butterfly valve type Air cleaner Semi dry type Governor Electronic control Lubrication system Forced splash Oil capacity qt L 19 0 22 Starting system Recoil starter Stopping system Primary circuit ground Fuel Automotive unleaded gasoline 87 octane Alternator Model KD10 Generator type Multi pole rotation Generator structure Self ventilation drip proof alternator Excitation Self excitation Magnet type Voltage regulation system Plush width modulation Phase Three phase Rotating direction Clockwise Viewed from the generator Frequency regulation AC DC AC conversion 2011 Kipor Power Systems Inc 2 Performance Model IG1000 Maximum output AC 1 0KVA Rated output AC 0 9KVA Rated output DC 100W Rated frequency 60HZ Rated voltage AC 120V Rated voltage DC 12V Rated current AC 7 5A Rated current DC 8 3A Power factor 1 0 Voltage variation rate Momentary Average Average time 10 max 1 5 max 3 sec max Voltage stability 1 Frequency variation rate Momentary Average Average time 1 max 1 max
10. 10 012 10 024 0 3965 10 070 Connecting rod big end inner diameter Standard in mm Service limit in mm 0 5911 0 5915 15 015 15 025 0 5937 15 080 61 2011 Kipor Power Systems Inc Crankshaft neck outer diameter Standard in mm Service limit in mm 0 5896 0 5899 14 975 14 985 0 5866 14 900 Connecting rod big end side clearance Standard in mm Service limit in mm 0039 0236 0 1 0 6 0 0315 0 8 62 2011 Kipor Power Systems Inc Oil film clearance of connection rod big end 1 Wipe all oil from the surface of the crankshaft neck 2 Set the plastic wire feeler at the crankshaft neck and install the connecting rod Tighten the bolt to the prescribed torque being careful not to rotate the crankshaft The tightening torque is 5 9 7 4 ft lb 8 10 N m 3 Disassemble the connecting rod and measure the plastic wire feeler thickness 4 Replace the connecting rod if the clearance exceeds the service limit Standard in mm Service limit in mm 0 0012 0 0019 0 030 0 050 0 0039 0 10 63 2011 Kipor Power Systems Inc Camshaft bearing inner diameter tappet shaft bearing inner diameter cylinder block Standard in mm Service limit in mm 0 1976 0 1988 5 02 5 05 0 2008 5 10 Camshaft bearing inner diameter tappet shaft bearing inner diameter gear case cover Standard in mm Se
11. Ignition system Fill in oil to the required level Use spark plug UR5 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 Normally you should see the spark jump the electrode gap when the plug is firing 13 Don t pull the recoil starter while touching the high tension wire with wet hands High voltage generates which is very dangerous Fire may be caused if fuel spilled around the spark plug so make sure that you test after draining off fuel completely Fuel inside cylinder will be burnt if the spark plug is near the hole so please turn off the engine first Pull the recoil starter several times to release the unborn gas in the cylinder 2011 Kipor Power Systems Inc 3 2 Hard Starting Continued 14 Measure the spark plug gap and perform the spark plug test Gap 024 028 in 0 6 0 7mm Perform the spark test again using a new spark plug Good spark Replace the spark plug No spark No spark Check the trigger Abnormal Replace the trigger or readjust trigger clearance Check the ignition coil resistance and high pressure cable high pressure insulation cap Inspection or replace wire harness Abnormal Rep
12. check the conduction conduct is normal 4 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 and allow to dry 5 Dip the element in clean engine oil and squeeze out all the excess oil 6 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 7 Install the air cleaner cover Be sure that the air cleaner cover seals are set securely 8 Install the maintenance cover securely 21 2011 Kipor Power Systems Inc Caution 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 Never run the engine with no element or a damaged element Engine damage will result 4 5 Spark plug Inspection Cleaning 1 Remove the spark plug cap and remove the spark plug 2 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 accor
13. in 4 050 48 2011 Kipor Power Systems Inc 12 Crankcase cover Camshaft drive chain 12 1 Disassembly 12 2 Crankcase oil tray disassembly and reassembly 1 Clean any remaining gasket material from the cylinder block and crankcase oil tray 49 2011 Kipor Power Systems Inc 2 Apply a 0 040 0 059 in 1 1 5 mm layer of liquid gasket material 1207B or equivalent evenly on the sealing face of the crankcase oil tray 3 Reassemble the crankcase cover in the reverse order of disassembly Caution Make sure to reassemble the crankcase oil tray three minutes after applying the gasket material 12 3 Crankshaft reinstallation 1 Revolve the crankshaft slowly placing the timing mark pointing up 2 Install the valve tappet move the tappet aside and then reassemble the camshaft Note that the timing mark on the camshaft and driving gear should be oriented downward and aligned with the timing mark on the timing gear 50 2011 Kipor Power Systems Inc 12 4 Crankcase cover assembly 1 Remove any remaining gasket material on the cylinder block and crankcase cover 2 Apply a 0 040 0 059 in 1 1 5 mm layer of liquid gasket material 1207B or equivalent evenly on the cylinder block sealing face 3 Reassemble the crankcase cover in the reverse order of disassembly Caution Install the crankcase cover on the cylinder block 3 minutes after applying the ga
14. skills required to perform the tasks safely Be sure that the engine is off before you begin any maintenance or repairs This will reduce the possibility of several hazards Carbon monoxide poisoning from engine exhaust Burns from hot parts Injury from moving parts Do not run the engine unless the instructions tell you to do so Keep your hands and clothing away from rotating parts 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 6 2011 Kipor Power Systems Inc 7 2 3 Service rules Use genuine KIPOR or KIPOR recommended parts and lubricants or their equivalents Parts that do not meet Kipor s design specifications may damage the engine Use the special tools designed for the product Always install new gaskets O rings etc when reassembling components Clean parts in cleaning solvent upon disassembly Lubricate any sliding surfaces before reassembly After reassembly check all parts for proper installation and operation 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 Use only metric tools when servicing this engine Metric bolts nuts and screws are not interchangeable wit
15. torque values for fasteners that are not listed in this table 2011 Kipor Power Systems Inc 11 3 Troubleshooting This troubleshooting section contains troubleshooting trees organized by common groups of symptoms Some testing information is contained in these sections The following chapters of this manual focus on individual components and sub assemblies which will give you the assembly and reassembly procedures along with detailed specifications and testing procedures 3 1 General symptoms and possible causes Engine does not start or hard starting Fuel filter clogged Clean Fuel tank tube clogged Clean Fuel switch clogged Clean Carburetor faulty Readjust and clean Ignition coil faulty Inspect and replace Spark plug faulty Inspect and replace Trigger faulty or trigger clearance faulty Inspect and replace Spark plug cap looses Fix it securely Low oil alarm faulty Inspect and replace Ignitor faulty Inspect and replace Ignition winding faulty Inspect and replace Throttle opening fault Set in fully close or half close position Engine speed does not stabilize too high or too low Carburetor faulty Adjust and or disassemble and clean Throttle control motor stepping motor faulty Inspect and replace Inverter unit faulty Inspect and replace Valve clearance misadjusted Readjust 2011 Kipor Power Systems Inc 3 2 Hard starting
16. valve clearance Valve clearance Intake 0031 0039 in 0 08 0 10mm Exhaust 0039 0059 in 0 10 0 15 mm 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 25 2011 Kipor Power Systems Inc 6 Clean the liquid gasket of the cylinder block and cylinder head cover Apply liquid gasket Three Bond 1207B or equivalent to the cylinder block installation surface as shown 7 Install all parts in the reverse order of removal 4 7 Fuel tank Fuel filter Caution 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 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 th
17. 00P or an IG2600P Connection to an IG2000P built before 2011 is not permitted There are two approved Kipor parallel kits One has a maximum capacity of 30 amps and has a single 30 amp receptacle The other has a capacity of 50 amps and has one single 20 amp and one single 30 amp receptacle Both receptacles are controlled by circuit breakers See the operator s manual for correct operation of the parallel generators and the parallel kits Parallel Operation Troubleshooting First check that both generators are operating in accordance with their output specifications The max and rated output of both generators should be confirmed All troubleshooting should be performed with the smart throttle in the off position If there is no output on the parallel panel check the following Condition Cause Corrective Action The output lights on both generators are green Overload on parallel panel Reduce load on panel Reset Circuit breakers The output lights on both generators are green Defective parallel receptacle or cable Check receptacle for continuity Check parallel cables for continuity from generator panel to parallel receptacle The output lights on both generators are green No signal from inverter module Check all inverter connections Replace inverter module One or more generators is showing overload but total load is within specifications Inv
18. 1 sec max Frequency stability 0 1 Insulation resistance 10M min AC circuit protector 8 8 A DC circuit protector 10 A Fuel tank capacity gal L 69 2 6 Operating hours 4 Noise level NL FL 23 7 m 60 65 dB 2011 Kipor Power Systems Inc 1 2 WIRING DIAGRAM IG1000 through 2010 Model Year 3 2011 Kipor Power Systems Inc IG1000 2011 Forward 4 2011 Kipor Power Systems Inc IG2000P 2011 forward 5 2011 Kipor Power Systems Inc 2 SERVICE INFORMATION 2 1 The importance of proper servicing Proper servicing is essential to the safety of the operator and the reliability of the generator Any error or oversight made by the technician while servicing can easily result in faulty operation and or damage to the equipment or injury to the operator 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 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 and safety equipment When performing maintenance or repairs be especially careful of the following Read the instructions before you begin and be sure you have the tools and
19. 3 955 3 970 mm 3 900 mm Guide I D IN EX 0 1575 0 1579 in 0 2598 in 4 000 4 012 mm 4 060 mm Valve spring Free length IN EX 0 925 in 0 866 in 23 5 mm 22 mm Cam wheel Cam height 1 101 1 103 in 1 062 in 27 97 28 03 mm 26 97 mm Camshaft O D 0 1963 0 1967 in 0 1949 in 4 988 4 996 mm 4 950 mm Camshaft bearing I D 0 1976 0 1988 in 0 2008 5 02 5 05 mm 5 10 mm Rocker arm I D Rocker arm 0 1575 0 1579 in 0 2598 in 4 000 4 012 mm 4 050 mm O D Rocker arm shaft 0 1574 0 1579 in 0 1590 in 3 988 3 996 mm 3 950 mm I D Rocker arm shaft bearing 0 1574 0 1579 in 0 1594 in 4 000 4 012 mm 4 050 mm Spark plug Gap 0 024 0 028 in 0 6 0 7 mm Ignition coil Resistance Primary side 0 8 1 3 Second side 15 21 k Pulse coil Trigger Air gap 0 020 0 0295 in 0 5 0 75 mm Resistance 80 130 Part Item Type Standard Ignition winding Resistance Green Yellow Green 0 50 0 70 Outer charging winding Resistance Blue Blue 0 16 0 20 Sub winding Resistance White White 0 25 0 35 Main winding Resistance Black Black 2 0 3 0 2 7 Torque values Item Specification Tightening torque Ft lb N m Connection rod bolt M5X0 8X25 5 9 7 4 8 10 Spark plug M10X1 0X13 11 13 Flywheel nut M10X1 25 48 52 Standard torque M5 Bolt nut 4 4 6 0 6 8 M6 Blot nut 5 9 7 4 8 10 Note Use standard
20. Adjust Valve clearance Check Adjust Fuel tank and filter Clean Fuel line Check Every 2 year Replace if necessary Note Service more frequently when operating in dusty areas Service by KIPOR authorized service center 4 2 Engine oil Checking for the oil level Stop the engine and check the oil level be sure to put the engine on a flat and level surface when checking 1 Loosen the maintenance cover screw and remove the cover 2 Remove the oil filler cap and check the oil level 19 2011 Kipor Power Systems Inc 3 If the oil level is low add to the edge of the oil filler port Replace the engine oil 1 Remove the oil dipstick and oil drain bolt drain out dirty oil 2 Reinstall the oil drain bolt tightly 3 Fill with fresh oil of the proper viscosity see operator s manual 4 Check the oil level 5 Tighten the oil dipstick Drain the used oil while the engine is warm Warm oil drains quickly and completely Avoid burns from hot oil 4 3 Checking 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 20 2011 Kipor Power Systems Inc 2 Stop engine disconnect oil alarm connector check the connector conduction no conduct is normal 3 Drain out the oil inside engine and
21. Install the spark plug and ground the electrode Check the spark Install a compression gauge in the spark plug hole and check the cylinder compression by pulling the recoil starter rope several times Normal Install the spark plug securely Restart the engine according to the starting procedure Normal compression Low cylinder compression 1 Check the valve clearance 2 Check for carbon deposits in the combustion chamber 3 Check for worn guides and seals 4 Check for worn piston piston ring or cylinder No spark or weak spark Perform the ignition system troubleshooting Clean the electrode and restart Ensure the choke is not closed If flooding is severe check the carburetor float valve Wet Check the fuel level in the tank Loosen the drain screw and check whether fuel reached the float chamber and the oil level Remove the spark plug and check for wet or fouled electrode Dry Check for blockage in the carburetor intake port and nozzle Normal Abnormal Check the fuel lines for blockage Sufficient fuel No fuel Add fuel and restart the engine 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 80 psi 0 55Mpa 12 2011 Kipor Power Systems Inc C
22. Y 49 12 5 INSPECTION 49 13 CRANKSHAFT PISTON AND CONNECTING ROD 52 13 1 DISASSEMBLY 52 13 2 PISTON 53 13 3 INSPECTION 54 13 APPENDIX A CAPACITOR 66 13 APPENDIX B CARB CERTIFIED UNITS 68 13 APPENDIX C PARALLEL OPERATION 69 iv 2011 Kipor Power Systems Inc v This page intentionally blank 2011 Kipor Power Systems Inc 1 1 SPECIFICATIONS and WIRING DIAGRAM 1 1 SPECIFICATIONS Dimensions and weights Model IG1000 IG1000P Overall Length in mm 18 1 460 Overall Width in mm 9 8 248 Overall Height in mm 15 6 395 Net Weight in Kg 30 8 14
23. alve clearance 2 Check for carbon deposits in combustion chamber 3 Check the piston piston ring and cylinder for damage Measure the cylinder compression Abnormal Normal Perform the throttle control system test Perform the generator troubleshooting following the section onf No or low AC output Abnormal Check the AC output Normal Abnormal Check the throttle control motor Replace the throttle control motor Normal Replace the inverter unit 2011 Kipor Power Systems Inc 3 7 Smart system doesn t work with zero load or engine speed doesn t increase with Smart system on and load connected Check the AC output Perform the generator troubleshooting following the section on No AC or low voltage Abnormal Normal Check the throttle control motor Replace the throttle control motor Abnormal Normal Check the Smart Throttle switch Check Smart switch connection wire Repair or replace the wire harness Abnormal Normal Normal Replace the smart Throttle switch Abnormal Replace the inverter unit 3 8 No or low AC output Disconnect the load and restart the engine ON Is the overload indicator light ON OFF Is the engine speed normal Smart switch ON 4200 100rpm OFF 5500 100rpm Abnormal Perform the throttle control system test Normal Abnormal Stop the engine and check the AC receptacle Replace the AC receptacle Normal Disconn
24. d with the asked valve Spark plug resistance 3 9K 22 2011 Kipor Power Systems Inc 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 024 028 in 0 6 0 7mm Standard spark plug UR5 0 6 0 7 5 Install the plug finger tight to seat the washer and then tighten with a plug wrench Torque valve is 8 9 6 ft lbs 11 13 N m 4 6 Valve clearance Caution 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 baffle 23 2011 Kipor Power Systems Inc 2 Remove the four tighten bolts and disassemble the cylinder cover Don t remove the cylinder cover with excessive force as it may deform Replace the cylinder cover if it is deformed 3 Remove the spark plug screw the dial indicator in the spark plug hole Rotate the rotor in a clockwise movement and set the piston at top dead center Caution Make sure both the intake and exhaust valves are closed 24 2011 Kipor Power Systems Inc 4 Insert a feeler gauge between the rocker arm and the valve and measure the
25. e 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 26 2011 Kipor Power Systems Inc 4 8 Fuel pump and hoses Caution 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 2 Make sure the negative pressure tube is firmly connected to the port on the engine block See page 37 3 Check the fuel tube for deterioration cracks and gasoline leakage If there is any abnormality in the fuel tube replace the tube 4 Check the diaphragm tube for deterioration crack and oil leakage If there is any abnormality in the diaphragm tube replace the tube 5 Check to see whether water or foreign material has been accumulated in the fuel pump If there is water or foreign material accumulated in the pump replace the fuel pump 6 Check the fuel switch and fuel duct blow away the foreign matter with high pressure gas with oil switch turned on 7 After assembly check for gasoline leakage from each pa
26. ect the main winding and sub winding CG 6p connector on inverte r unit Start the generator and measure the voltage between pins 1 amp 4 2 amp 4 1 amp 2 Each reading should be at least 290 volts 1 Check and repair stator wiring harness or replace stator 2 Check rotor magnetism If decreasing replace the rotor Abnormal Normal 17 Replace the inverter unit 2011 Kipor Power Systems Inc 3 9 No DC output Normal Abnormal Check the engine speed Abnormal Perform the throttle control system troubleshooting Normal Abnormal Replace the DC receptacle Check the DC receptacle Normal Check the rectifier Abnormal Replace the fuse Check the 5 amp fuse Normal Normal The rotor loses excitation replace the rotor Measure the resistance between the two blue wires on the rectifier Abnormal Check and repair the wiring harness or replace the stator Resistance 0 16 0 20 Replace the rectifier 18 2011 Kipor Power Systems Inc 4 Maintenance 4 1 Maintenance schedule Regular service period Each use First month or 20 Hrs Every 3 months or 50Hrs Every 6 months or 100 Hrs Every year or 300 Hrs Item perform at every indicated month or operating hour interval whichever comes first Engine Oil Check Replace Air filter Check Clean Spark plug Clean Adjust Spark catcher Clean
27. erter module is not balancing loads equally among both generators Check all inverter connections Replace inverter module 69 2011 Kipor Power Systems Inc 70 2011 Kipor Power Systems Inc
28. h non metric fasteners The use of incorrect tools and fasteners will damage the engine 2 4 Electrical precautions Hold the connector body to disconnect the connector Do not disconnect by pulling the wire harness To disconnect the locking connector be sure to unlock first and then disconnect Check the connector terminals for bend excessive extrusion missing terminals or other abnormalities before connecting the connector To connect insert the connector as far as it goes If the connector is a locking type be sure that it is locked securely 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 Set the harness clips in the specified places of the frame securely and secure the wire harnesses Clamp the cables securely Clamp the wire harnesses securely so that they do not interfere with the rotating parts moving parts and hot parts Route and connect the wire harnesses properly Be sure that the harnesses are not slack twisted or pulled overly taut 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 2011 Kipor Power Systems Inc If a wire harness must co
29. here should be continuity when the micro switch is depressed Rectifier Measure the on or off positive pressure fall of rectifier with control potentiometer the measurement should accord with the standard as shown in the chart Positive Negative 1 2 3 4 1 OFF OFF OFF 2 ON OFF OFF 3 ON ON ON 4 ON OFF OFF 36 2011 Kipor Power Systems Inc 8 Housing Fuel tank 8 1 Housing disassembly and reassembly Left housing case 37 2011 Kipor Power Systems Inc 8 2 Fuel tank assembly Caution 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 38 2011 Kipor Power Systems Inc 9 Recoil starter Air conduct cover Ignition coil Air conduct plate 9 1 Disassembly Reassembly 39 2011 Kipor Power Systems Inc 9 2 Air conduct plate Disassembly Reassembly 40 2011 Kipor Power Systems Inc 9 3 Disassembly and reassembly of recoil starter 1 Set the spring into the starter reel and hang the spring outer hook inside the reel groove 41 2011 Kipor Power Systems Inc 2 Smear lubrication grease on the starter outer shell claw install the starter
30. istance 0 50 0 70 2 Outer charging winding Measure the resistance between the two blue terminals Resistance 0 12 0 15 3 Sub winding Measure the resistance between the two sub winding terminals Resistance White white 0 25 0 35 4 Main winding Measure the resistance among the terminals of the main winding Resistance Black black black 2 0 3 0 45 2011 Kipor Power Systems Inc 5 Trigger Attach the two test leads to the trigger and measure the resistance Trigger resistance 80 130 10 3 Trigger adjustment Adjust the clearance between trigger and the projection of the rotor Trigger clearance 0 0197 0 0275 in 0 50 0 75 mm Insert a feeler gauge between the trigger and the projection of the rotor loosen the trigger fixed plate bolt to adjust the clearance slightly Never move the plastic part of trigger 46 2011 Kipor Power Systems Inc 11 Cylinder cover Rocker arm 11 1 Disassembly Reassembly 47 2011 Kipor Power Systems Inc 11 2 Inspection Rocker arm outer diameter Standard in mm Service limit in mm 0 1570 0 1573 3 988 3 996 0 1555 3 950 Rocker arm inner diameter of inlet exhaust valve Standard in mm Service limit in mm 0 1575 0 1579 4 000 4 012 0 2598 4 050 Inner diameter of rocker arm bearing Standard in mm Service limit in mm 0 1575 0 1579 4 000 4 012 0 2598
31. lace the ignition coil Normal Check the resistance of motor ignition winding Replace the motor stator Abnormal Replace the engine switch No spark Check the engine switch Good spark Replace the low oil alarm Disconnect the low oil alarm and perform spark test Good spark No spark Remove the control panel Perform spark test with a new ignition module Good spark Replace the ignition module No spark Normal Normal 2011 Kipor Power Systems Inc 3 3 Engine oil level is low but engine does not stop Defective oil switch Drain out oil completely disconnect alarm connection wire and check the continuity between alarm outlet terminal and ground Replace the oil level alarm Ignition module fault replace module Continuity Reset the alarm connection wire disconnect ignition module and check the continuity between the plug orange wire and ground No continuity Repair or replace the wire harnesses Continuity No continuity 3 4 Engine stops running Throttle is at the correct position Check the oil level and oil alarm Fill in oil and restart the engine Sufficient oil Oil alarm Check whether there is enough fuel in the fuel tank Add fuel and restart the engine No fuel Sufficient fuel Check the fuel switch and fuel filter for blockage Check the fuel supply line for blockage Clear or replace the fuel supply line Blocked No blocked
32. ntact 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 with electrical insulating tape If the wire harness has a grommet set the grommet securely Take care not to pinch the wire harnesses during installation of a part If a wire harness has damaged insulation repair by winding with electrical insulating tape When using an electrical tester like a volt ohm meter or clamp on meter read the manufacturer s operating instructions carefully before operating the tester Be sure that the tester battery is fully charged and the meter is functioning properly 2 5 Serial number The generator serial number identifies your particular unit and is important when ordering parts and accessories It is also used by your dealer and distributor for warranty administration The generator serial number is stamped on the engine block to the right of the oil dipstick It is also on a label on both ends of the generator carton as well as the certificate of quality 8 2011 Kipor Power Systems Inc 9 2 6 Maintenance standards Part Item Standard mm Service limit Engine Maximum speed without load 5500 100 rpm Cylinder Sleeve I D 1 712 1 714 in 1 716 in 43 500 43 520 mm 43 595 mm Piston Skirt O D 1 711 1 712 in 1 707 in 43 460 43 480 mm 43 350 mm Pin bore I D 0 3937 0 3940 in 0 3955 in 10 002 10 008 mm 10 050 mm Pis
33. put power supply it has the potential to store a high voltage charge and should be discharged prior to testing Unplug the 2p connector and short circuit the capacitor by placing the end of an insulated screwdriver across the two terminals 66 2011 Kipor Power Systems Inc Terminals Do not touch the exposed terminals nor attempt to take any measurements before discharging the capacitor Use the capacitance checking mode of a multimeter Replace the capacitor if any reading is outside the standard value of 10uF 5 67 2011 Kipor Power Systems Inc Appendix B CARB Certified Units The fuel tank fuel cap indicator and hoses are specially designed and constructed to prevent fuel vapors from permeating and be released into the atmosphere The emission control system has the following components 68 Other than routine inspection of the tank cap and fuel lines there are no maintenance or service requirements C U 05 012 Fuel Hose X6800BM Q 08 006 Fuel Tank Certification No Certification No Fuel Hose Fuel Hose 2011 Kipor Power Systems Inc Appendix C Parallel Operation Beginning with the 2011 model year an IG1000P model was introduced The IG1000P can be connected through a parallel kit to a 2011 IG1000P an IG20
34. r Standard in mm Service limit in mm 0 0008 0 0024 0 02 0 06 0047 0 120 58 2011 Kipor Power Systems Inc Piston skirt outer diameter Standard mm Service limit mm 57 960 57 980 57 850 Clearance between piston and cylinder Standard in mm Service limit in mm 0 0078 0 0165 0 020 0 042 0 0047 0 120 Side clearance of piston ring Standard in mm Service limit in mm 0 0008 0 0024 0 02 0 06 0 0059 0 15 Piston ring end clearance Locate the piston ring into cylinder with piston top and measure the piston end clearance Standard in mm Service limit in mm 0 0059 0 0098 0 15 0 25 0 0394 1 0 59 2011 Kipor Power Systems Inc Piston ring height Standard in mm Service limit in mm The 1st ring 0 0030 0 031 0 77 0 79 0 028 0 70 The 2nd ring 0 038 0 039 0 97 0 99 0 0354 0 90 Piston pin outer diameter Standard in mm Service limit in mm 0 3934 0 3937 9 994 10 000 0 3920 9 950 Piston pin bore inner diameter Standard in mm Service limit in mm 0 3937 0 3940 10 002 10 008 0 3955 10 050 60 2011 Kipor Power Systems Inc Clearance between piston pin and piston pin hole Standard in mm Service limit in mm 0 00008 0 00055 0 002 0 014 0 00314 0 080 Connecting rod small end inner diameter Standard in mm Service limit in mm 0 3942 0 3946
35. range 2 1 4 3 33 2011 Kipor Power Systems Inc 7 Control panel 7 1 Removal Installation 34 2011 Kipor Power Systems Inc 7 2 Inspection a Control panel AC receptacle Check the electrode contact disk inside receptacle if it is burnt or discolored replace for it DC receptacle After checking the fuse 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 There should be continuity with the switch ON and no continuity with the switch OFF Ignition Module Pull off the 10P receptacle from the module measure the resistance by connecting one testing pen with the metal outer case of engine and the other testing pen with the 10P connector Color Circuit unit Standard resistance Blue Primary coil of the ignition coil 0 8 1 3 Orange Oil level alarm There should be no continuity with correct oil level Yellow Trigger coil 80 130 Yellow Green Ground wire Continuity Green Igniter unit power coil winding 0 5 0 7 Red Engine switch There should be no continuity with the switch ON continuity with the switch OFF 35 2011 Kipor Power Systems Inc Engine switch Check the continuity of connector t
36. reel Revolve the reel anticlockwise to hang the spring inner hook on the starter outer shell claw 3 Make a 8 knot at one end of the rope pass the other end through the reel hole Wind the reel anticlockwise 6 turns to fix the reel 42 2011 Kipor Power Systems Inc 4 Pull rope through from starter outer shell hole completely pass it through the handle and make a figure eight knot then turn off handle cover Loosen the reel to release tension on the spring taking care not to allow the reel to pop out 5 Install the revolving axis revolving axis parts and friction spring fix it with bolts 6 Pull the starter for several times and check the revolving axis 43 2011 Kipor Power Systems Inc 9 4 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 3 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 resistance 15 21k 44 2011 Kipor Power Systems Inc 10 Alternator Trigger 10 1 Alternator Disassembly Reassembly 10 2 Inspection 1 Ignition winding Measure the resistance between the green terminal and yellow green terminal Res
37. rt 27 2011 Kipor Power Systems Inc 4 9 Spark arrestor Caution Make sure the muffler has cooled completely before attempting any maintenance on this part 1 Remove the rear cover 2 Disassemble the arrestor from muffler 3 Remove the carbon from the spark arrestor steel mesh with a stiff wire brush Check for damage and replace it if necessary 4 Install the removed parts in the reverse order of removal 28 2011 Kipor Power Systems Inc 5 Muffler Caution Muffler removal installation must be performed with the engine cold Disassembly Reassembly 29 2011 Kipor Power Systems Inc 6 Air filter Carburetor Caution Loosen the drain oil bolt and drain out fuel before disassembly Keep heat flame and sparks away 6 1 Air filter removal and installation 6 2 Carburetor removal and installation 30 2011 Kipor Power Systems Inc 6 3 Stepping motor removal and installtion 31 2011 Kipor Power Systems Inc 6 4 Carburetor exploded drawing Note With the exception of changing the main jet for altitude compensation no adjustments to this carburetor are permitted under EPA and CARB guidelines No repair parts will be furnished
38. rvice limit in mm 0 1976 0 1988 5 02 5 05 0 2008 5 10 64 2011 Kipor Power Systems Inc Bearing vibration Clean the bearing and dry it check the clearance between crankshaft journal and connecting rod big end by rotating the bearing by hand Replace the bearing if there is abnormal noise or vibration 65 2011 Kipor Power Systems Inc Appendix A Capacitor Beginning with models built in December 2007 and ending in July 2008 a capacitor was added to reduce electro mechanical interference and eliminate problems with some digital clocks not displaying the time properly This was an interim solution and all later models had an inverter module modification to eliminate the capacitor 1 LOCATION The capacitor was placed in the output lines between the inverter and the AC receptacles It is physically located inside the service door to the right of the oil dipstick It is mounted on a bracket that bolts to the base plate The base plate was modified to accept the new bracket There is a 2p connection behind the receptacles TO CAPACITOR Capacitor Installation Connection to receptacle 2 TROUBLESHOOTING AND TESTING Check the capacitor when troubleshooting issues regarding digital clock displays Should the capacitor fail there will be no impairment of any other generator function or output As the capacitor is connected directly to the out
39. sket material 4 Screw on the crankcase cover bolts slowly and tighten to the prescribed torque 12 5 Inspection Inspection of the oil alarm 1 Place the oil alarm in the position shown below There should be no continuity between the oil alarm output wire and copper ground wire 2 Turn the oil alarm 180 and check again there should be continuity 3 Immerse the oil alarm completely in oil check the float there should be no continuity Caution Wait two minutes after immersing the alarm in oil before measuring 51 2011 Kipor Power Systems Inc Cam height Standard in mm Service limit in mm 1 101 1 103 27 97 28 03 1 062 26 97 Cam inner diameter Standard in mm Service limit in mm 0 1976 0 1988 5 02 5 05 0 2008 5 10 Camshaft outer diameter tappet shaft outer diameter Standard in mm Service limit in mm 0 1963 0 1967 4 988 4 996 0 1949 4 950 52 2011 Kipor Power Systems Inc Valve tappet inner diameter Standard in mm Service limit in mm 0 1968 0 1975 5 000 5 018 0 1988 5 050 53 2011 Kipor Power Systems Inc 13 Crankshaft Piston 13 1 Disassembly Reassembly 54 2011 Kipor Power Systems Inc 13 2 Piston Assembly of piston ring Caution Set the manufacture label up Pay careful attention not to mix the location of the 1
40. st ring and 2nd ring Check the piston ring for flexibility after installation Stagger each piston ring opening 120 apart 55 2011 Kipor Power Systems Inc There may be two different kinds of piston rings for the same model generator They can be distinguished by different manufacture labels Don t intermix piston rings of different manufacture on the piston 13 3 Inspection Free length of valve spring Standard in mm Service limit in mm 0 925 23 5 0 866 22 56 2011 Kipor Power Systems Inc Valve stem outer diameter Standard in mm Service limit in mm Intake valve 0 156 0 157 3 965 3 980 0 1535 3 900 Exhaust valve 0 1557 0 1562 3 955 3 970 0 1535 3 900 Valve guide pipe inner diameter Standard in mm Service limit in mm Intake Exhaust valve 0 1575 0 1579 4 000 4 012 0 2598 4 060 Clearance between valve stem and valve guide pipe Standard in mm Service limit in mm Intake valve 0 0008 0 0018 0 020 0 047 0039 0 10 Exhaust valve 0 0012 0 0022 0 030 0 057 0047 0 12 57 2011 Kipor Power Systems Inc Cylinder inner diameter Standard in mm Service limit in mm 1 712 1 714 43 500 43 520 1 716 43 595 Piston skirt outer diameter Standard in mm Service limit in mm 1 711 1 712 43 460 43 480 1 707 43 350 Clearance between piston and cylinde
41. ton pin O D 0 3934 0 3937 in 0 3920 in 9 994 10 000 mm 9 950 mm Piston ring 1st ring Height 0 030 0 031 in 0 028 in 0 77 0 79 mm 070 mm Ring side clearance 0 0008 0 0024 in 0 0059 in 0 02 0 06 mm 0 15 mm Ring end clearance 0 0039 0 0098 in 0 0314 0 10 0 25 mm 0 80 mm Width 0 063 0 071 in 0 055 in 1 60 1 80 mm 1 40 mm 2nd ring Height 0 038 0 039 in 0 0354 in 0 97 0 99 mm 0 90 mm Ring side clearance 0 0008 0 0024 in 0 0059 in 0 02 0 06 mm 0 15 mm Ring end clearance 0 0039 0 0098 in 0 0314 0 10 0 25 mm 0 80 mm Width 0 071 0 078 in 0 063 in 1 80 2 00 mm 1 60 mm Oil ring Height 0 053 0 058 in 0 049 in 1 35 1 48 mm 1 25mm Ring side clearance 0 0008 0 0067 in 0 0090 in 0 02 0 17 mm 0 23 mm Ring end clearance 0 0079 0 1180 in 0 0354 in 0 20 0 30 mm 0 90 mm Width 0 3942 0 3946 in 0 3965 in 2 00 2 40 mm 1 80 mm Connecting rod Small end I D 0 3942 0 3946 in 0 3965 in 10 012 10 024 mm 10 070 mm Big end I D 0 5911 0 5915 in 0 5937 in 15 015 15 025 mm 15 080 mm Crankshaft Crank pin O D 0 5896 0 5899 in 0 5866 in 14 975 14 985 mm 14 900 mm Valves Valve clearance Intake 0 0031 0 0039 in 0 08 0 10 mm Exhaust 0 0039 0 0059 in 0 10 0 15 Stem O D Intake 0 156 0 157 in 0 1535 in 2011 Kipor Power Systems Inc 10 3 965 3 980 mm 3 900 mm Exhaust 0 1557 0 1562 in 0 1540 in
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