Kipor KDE5000E 5000TA Service Manual[1]

KIPOR POWER PRODUCTS CO., LTD

GENERATOR SHOP MANUAL

KDE5000E

KDE5000TA

The Coast Distribution System, Inc.

January, 2007

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PREFACE

This manual covers the construction, function and servicing procedure of the Kipor KDE5000E and KDE5000TA Coast Distribution model generators. This manual is principally concerned with the generator specifications, function, troubleshooting and repair. See the owner’s manual for the preventive maintenance schedule and instructions. There is a separate manual to cover overhaul, repair and troubleshooting of the KM186FA diesel engine.

Careful observance of the instructions contained in this manual will result in safe and quality service work.

All information, illustrations, directions and specifications included in this publication are based on the latest product information available at the time of approval for printing.

KIPOR POWER CO., LTD, reserves the right to make changes without incurring any obligation whatever. No part of this publication may be reproduced without written permission.

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TABLE OF CONTENTS 1. Specifications and Data

1.1 Specifications ....................................................................................................4

1.2 KDE5000E wiring diagram................................................................................5

1.3 KDE5000TA wiring diagram ............................................................................6

1.4 Component Identification- KDE5000E..............................................................7

1.5 Component Identification- KDE5000TA ..........................................................8

1.6 Control Panel- KDE5000E ..............................................................................9

1.7 Control Panel- KDE5000TA .............................................................................9

1.8 KDE5000TA Digital Display Panel ...................................................................10

1.9 Serial number and bar code location ..............................................................11

2. Service Information .....................................................................................................12

2.1 The importance of proper servicing .................................................................12

2.2 Important safety precautions.............................................................................12

2.3 Service rules ....................................................................................................12

2.4 Electrical precautions ......................................................................................13

2.5 Generator Service Standards............................................................................14

2.6 Fasteners and torque values ..........................................................................15

2.7 Digital panel protection values ........................................................................15

2.8 Troubleshooting ...............................................................................................15

3. Generator Repair..........................................................................................................23

3.1 Start switch ......................................................................................................23

3.2 Voltmeter .........................................................................................................24

3.3 Circuit breaker .................................................................................................24

3.4 Oil alert ..............................................................................................................25

3.5 Generator ........................................................................................................28

4. Electrical Component Illustrations................................................................................30

4.1 Receptacle wiring ............................................................................................30

4.2 AVR adjustment.................................................................................................31

4.3 Battery charge regulator ..................................................................................32

4.4 Current transformer...........................................................................................32

4.5 Rotor checking ................................................................................................34

4.6 Stator test points ..............................................................................................35

4.7 Main stator winding check.................................................................................36

4.8 Stator secondary and sampling winding check ...............................................37

4.9 Charge winding check .....................................................................................38

4.10 Carbon brush check........................................................................................38

5. KDE5000TA display panel ..........................................................................................39

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1. SPECIFICATIONS AND DATA

1.1 Specifications

Model

Item KDE5000E KDE5000TA

Rated frequency (Hz) 60 60

Rated power (kVA) 4.5 4.5

Rated voltage (ACV) 120/240 120/240

Rated current (ACV) 37.5/18.8 37.5/18.8

Rated speed (rpm) 3600 3600

Phase Single phase

Power factor 1.0

Excitation mode Self excitation constant voltage (AVR)

DC output 12V/8.3A

AC Receptacles 2 120 15A, 1 30A Twistlock, 1 30A 120/240,

Structure mode Open frame Enclosed

Coupling method Transmission rigid connection

Gross weight lbs. (kg) 209 (95) 376 (171)

Generating set

Overall dimensions LxWxH in (mm) 28.3x19.4x25.6

(720x480x845)

36.6x20.3x29.7

(930x515x755)

Model

Item KDE5000E KDE5000TA

Model KM186FAG

Type 4-stroke, single-cylinder, air-cooled, direct

injection diesel engine

Max output (kW/rpm) 6.6

Bore x stroke in (mm) 3.4x2.8 (86x72)

Displacement in (L) 0.418

Cooling system Forced air-cooled system

Lubricating system Pressure splashing

Lube oil capacity qt. (L) 1.5 (1.65)

Starting system Recoil/electric Electric

Fuel Diesel

Fuel tank volume gal (L) 3.9 (15) 4.2 (16)

Run time at rated load- hrs 8 8.5

Engine

Low oil alarm system included

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1-2 KDE5000E wiring diagram

6

1-3 KDE5000TA wiring diagram

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1.4 Component Identification- KDE5000E

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1.5 Component Identification KDE5000TA

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1.6 Control panel- KDE5000E

OIL ALERT WARNING LAMP VOLTMETER

START SWITCH

CIRCUIT BREAKERS

20AMP 120VAC

GROUNDING STUD

DUPLEX

30 AMP 120VAC RECEPTACLE 30 AMP 120/240VAC RECEPTACLE

1.7 Control Panel KDE5000TA

START SWITCH

CIRCUIT BREAKERS

DISPLAY PANEL

20A

120VAC DUPLEX

RECEPTACLE

PANEL FUSE

GROUNDING STUD 30A 120VAC RECEPTACLE 30A 120/240VAC

RECEPTACLE

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1.8 KDE5000TA Digital Display Panel

The panel is designed to give the operator precise information regarding generator

operation and current loads. Additionally, should the generator experience a condition

necessitating shutdown, a fault code appears on the screen.

When running, the green “RUN” light should be illuminated. Press the function “FUNC”

button to change the display. A green light should appear above the digital readout to

indicate the current function. You have a choice of voltage (120 or 240), power (VA),

Frequency (HZ), total runtime in hours, and starting battery voltage.

Panel programming is explained in section 5.

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1.9 Serial number and bar code identification and location

The generator serial number identifies your particular unit and is important when ordering

parts and accessories. The bar code is used by your dealer and Coast Distribution for

warranty administration.

The serial number for the

KDE5000TA is located on the

air inlet plate to the left of the

diesel injection pump.

The serial number for the

KGE5000E can be found on

a stainless steel shroud

surrounding the alternator the

right of the engine.

The bar code is found in three

locations: on the generator,

on the packing crate or carton,

and on the inside cover of the

operator’s manual.

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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.

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.

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 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.

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

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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 with 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.

• If a wire 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 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

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2.5 Generator Service Standards

Winding Resistance standard (Ω) Standard value of voltage at No load (V)

Main Winding 0.75-0.85 240

Secondary Winding 2.5 135

Sampling Winding 0.5 16

Charge Winding* 2.5 13/13

Rotor Winding 40-45 70

*Charge receptacle removed from North American models but windings are present

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2.6 Fasteners and Torque Values

(1) KDE5000E

Torque Value Item Description

Inner diameter of

screw X length N.M Lbf

Front end cover Hexagonal flange face bolt M8X25 18 13

Rotor through bolt Hexagonal flange face bolt M10X210 50 36

Tighten bolt of

fore/back end cover Hexagonal flange face bolt M6X140 10 7

Frame power Hexagonal flange face bolt M10X45 40 29

Hexagonal bolt M10 40 29

Earth wire Hexagonal flange face bolt M6X12 9 7

Electromagnet Cross slotted pan head screw M3X5

Cross slotted pan head screw M4X8

Anti-hunting bracket Hexagonal flange face bolt M8X16 20 15

Oil tank Hexagonal flange face bolt M6X25 9 7


Decorating plate Hexagonal flange face bolt M6X25 9 7


Carbon brush Hexagonal flange face bolt M5X20

Rectification block Hexagonal flange face bolt M5X20

Earth wire Hexagonal flange face bolt M5X12

Back cover Hexagonal flange face bolt M5X12

AVR Hexagonal bolt M5

Oil tank assembly Cross slotted pan head screw M5X12

Cross slotted pan head screw M5X8

Nut M6 9 7

Panel Cross slotted pan head screw M6X16 9 7

Hydraulic pressure

regulator Hexagonal flange face bolt M6X18 9 7

Battery bracket Hexagonal flange face bolt M8X16 20 15


Hexagonal flange face bolt M6X12 9 7

Nnt M6 9 7

Battery Butterfly nut M6 9 7

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(2) KDE5000TA

Torque Value Item Description

Inner diameter of

screw X length N.m Lbf

Front end cover

British standard3/8

16 tooth bolt 30 22

Rotor through bolt Hexagonal flange face bolt M10X225 50 36

Tighten bolt of

front/back end cover Hexagonal flange face bolt M6X150 10 7

Frame power Hexagonal bolt M8 18 13


Earth wire Hexagonal flange face bolt M6X8 9 7

Muffler Hexagonal bolt M8 30 22

Fixed Hexagonal flange face bolt M8X25 20 15


Panel Cross slotted pan head screw M6X16 9 7

Nut M6 9 7

AVR Hexagonal flange face bolt M5X16

Carbon brush Hexagonal flange face bolt M5X20

Rectification Hexagonal flange face bolt M5X20

Earth wire Hexagonal flange face bolt M5X12

Back cover of motor Hexagonal flange face bolt M5X12

Oil tank Hexagonal flange face bolt M6X20 9 7

Fixed air cleaner Nut M6 9 7

Charging regulator Hexagonal flange face bolt M8X25 20 15

Bracket Hexagonal flange face bolt M6X12 9 7

Battery bracket Hexagonal flange face bolt M8X16 20 15




Battery Butterfly nut M6 9 7

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2.7 Digital Panel Protection Values

(1) Low oil pressure protection- oil pressure low for 5s: shutdown and display P-01

(2) Under frequency protection- output frequency = 57 Hz for 10 seconds: shutdown and

display P-02

(3) Over frequency protection- output frequency = 65HZ for 10 seconds: shutdown and

display P-02

(4) Under voltage protection- output voltage = 105V or 210V: shutdown and display P-03

(5) Over voltage protection- output voltage = 132V or 264V: shutdown and display P-03

(6) Over load protection- output current exceeds 21.2/42.4A: shutdown and display P-04

(7) Charge malfunction warning: no protection but display P-05

(8) High temperature- no protection or fault: water cooled engine models only

2.8 Troubleshooting

2.8.1 General symptoms and possible cause

(1) Diesel engine can not start or difficult to start (see engine repair manual)

Fault: Remedy:

Deteriorated diesel oil in fuel oil Drain the fuel oil, check and clean

Fuel oil is not sufficient Refill the fuel oil

Fuel cock is not at START position. Turn it to START position

Fuel delivery line to fuel tank is bent

or pipe is clogged

Check

Fuel filter is clogged Clean or replace

The injection pump does not deliver fuel Remove the high pressure fuel line, check for fuel

flow, repair or replace pump

Fuel injector does not deliver fuel Remove the fuel injector, check nozzle- clean or

replace

The governor lever of engine throttle is not at

START position

Switch on

Engine oil filter is clogged causing low oil

protection

Clean or replace

Solenoid fuel valve is clogged or does not work

because power is off

Check the 12V power supply and/or replace

solenoid valve

The governor lever of engine throttle is defective Check and replace as necessary

The ignition switch fails to engage starter Check battery condition then check switch

Starting motor is defective Replace

Oil alert switch won’t allow ignition Check and replace as necessary

The battery has is discharged Check battery and battery charge regulator

Valves are improperly adjusted Check or adjust valve clearance.

Engine is seized Check and observe the engine rotation,

disassemble the engine to determine reason for

failure.

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(2) Engine speed is unstable, too high or too low (see engine repair manual)

Fault: Remedy:

The fuel supply is insufficient Adjust or disassemble to clean

Injection pump or injector is defective Check or replace

Generator has an overload or short circuit fault Repair the fault

Engine governor spring is faulty Repair the fault

Valves out of adjustment Adjust

(3)The generator produces no AC power or the voltage is abnormal or fluctuating.

Fault: Remedy:

1. Circuit breaker fails to

function

Remove it and check for open circuit. The

resistance reading in multimeter should be “0”

2. The wiring of gauge panel is

loose

Check the wiring harness.

Gauge panel of

generating set

3. The connection of

receptacle is loose or contact

broken.

Check or replace receptacle

1. The stator leads are not

properly connected

Check the wiring harness

2.The four point output terminal

is cracked

Check or replace terminal

3. Short, open, or grounded

stator windings

Check resistance values of all windings.

Replace stator is shorted, open or grounded

4 Loss of magnetism in main

rotor

Check AVR

5. Short, open, or grounded

rotor windings

Check resistance values and replace rotor as

necessary

6. Carbon brush assembly

defective

Check resistance value at slip rings. Check

brushes for wear, weak spring tension

Alternator fault

7. Insulation resistance of

generator is too low.

Check insulation resistance of stator and rotor.

Replace stator and rotor as necessary.

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(3) AVR fault

1. Voltage can not be regulated Adjust or replace AVR

2. Generator set automatically stopped after

loading, current setting incorrect

Check output voltage, adjust or replace AVR

3. Electric component failed Replace AVR

4. Sampling signal but no exciting output Check exciting output voltage of AVR. Adjust and or

replace.

5. The voltage can not be established because

of insufficient residual voltage in the stator

Check that the voltage of main winding is 6 V or

more with AVR disconnected.

6. Power loss is increased because of higher

voltage output of the secondary winding

Check that the voltage of secondary winding should

not greater than 140 VAC

7. The voltage deviation of zero load and full

load is too large.

- Check AVR and stator.

- This may be caused by operating the generator in

too high an ambient temperature.

8. Overload shutdown caused by high power

factor loading

Check inductive loads for low power factor and

adjust size of load to rated power*

* Divide the appliance current draw by its power factor to determine the effect on the generator. A device pulling 40 amps with a power factor of .85 places a 47 amp draw on the generator (40/.85). In this example, the generator would experience an overload shutdown.

(4) Control panel fault

Fault: Remedy:

1. No display on screen.

2. Displays wrong code.

3. Generator cannot start.

- Check 12V power supply of the generator and check

wiring .

- replace screen

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2.8.2 Troubleshooting flow charts

(1) Hard starting

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(2) No AC voltage

22

(3) No Voltage Regulation

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(4) Generator shutdown

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3. GENERATOR REPAIR

3.1 Start switch

Check: Circuit should be closed when switched on. Circuit should be open when switched off. In starting position the circuit should be closed.

1 2 3 4 5 6 7

OFF --------- ---------- ---------- ----------

ON ---------- ---------

START ---------- ---------- ----------

.

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3.2 Voltmeter (KGE5000E)

Check generator output with a voltmeter. The reading should agree with the voltmeter. If the voltmeter has no output or it varies with the generator output, test and replace as necessary.

3.3 Circuit Breaker

Check: Measure the resistance at two ends of air switch with a multimeter. The resistance should be infinity when the circuit breaker is in the off position and zero when on.

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3.4 Oil alert PCB and pressure switch

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3.5 Generator

3.5.1 Check

(1) Front end cover: check for cracks

(2)Generator fan: check for missing or chipped blades

(3)Rotor: make sure it is clean and free of engine contaminants like grease and oil.

Normal measured resistance should comply with section 2.5. The copper windings

should be clean and bright with no trace of corrosion. Black or cracked windings indicate

a short necessitating replacement.

(4) Clip ring: It should be smooth without any defect or distortion. The semicircle of the

center boss should be clear. In case of distortion replace the clip ring

(5) Through bolt: tightening torque is 37-41 Lbf (50-55 N.m). This is essential to ensure

the generator won’t be damaged by scrubbing of the rotor and stator.

(6) Stator: Check the external enamel covered wire for defects after disassembly and

reassembly. Do not contact the copper windings with ground or pieces of sharp metal to

prevent scuffing.

Stator checks: Check the resistance of the main winding, secondary winding, sampling

winding and battery charge winding. The stator must be changed if any resistance reading

is outside the parameters. However, insure that there is continuity in the harness before

proceeding with a stator change.

(a) Main winding: Check resistance on the four position terminal board. You should have

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0.75 to 0.85 Ω between L1 and L2 and R1 and R2

(b) Secondary or sub winding: Locate the 4 pin connector at the top of the stator. Check

the resistance between the two blue green wires. The nominal value is 2.5 Ω.

(c) Sampling winding: On the same 4 pin connector, check the resistance between the

two yellow wires. The value is 0.5 Ω.

(d) Charge winding: Find the 4 pin connector at the top of the stator. There are only two

pins. The resistance value should be 2.5 Ω.

(7) Carbon brush: There should be no open circuit between lug and pole of the carbon

brush and no short circuit between the two poles. Check the brushes for wear. If the

brush wear is uneven or the length is less than 0.12 in. (3mm)

(8) Rear end cover: check for cracking.

3.5.2 Disassembly

(1) Open the rear end cover for open frame generator. Remove the cabinet, cooling plate,

left and right side plates, and muffler for TA model.

(2) Remove the alternator assembly with the harness. With the TA model, you must

remove the induced draft hood to get to the harness.

(3) Remove 4xM6x175M bolt from the rear end cover.

(4) Remove the stator.

(5) Secure the rotor to prevent it from dropping and remove the 10mm flange bolt.

(6) Remove the rotor with a puller.

3.5.3 Rotor Installation

Caution: Remove any dust and oil pollution from the crankshaft and rotor. Check the

resistance of the new part before installation.

1) Insert the semicircle clip ring into key groove.

2) Install the rotor on the crankshaft.

(3) Secure the rotor with a strap wrench and tighten the 10mm flange bolt: tightening

torque: 37.5 Lbf (50 N.m)

3.5.4 Stator Installation

(1) Before installing a new stator, check the resistance values of the new part.

(2) Adjust the spacing between the stator and rotor.

• Insert a feeler gauge between the stator winding and the projection of the rotor.

• Rotate the rotor one complete revolution.

• Secure the flange bolt connecting stator and front end cover. The locking torque is 7.5

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Lbf (10-13 N.m)

• The correct spacing is 0.020+/-0.004 in (0.25 +/- 0.1 mm)

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4. Electrical Component Illustrations

4.1 Receptacle wiring

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4.2 AVR Adjustment

34

4-3 Battery Charge Regulator

4.4 Current Transformer

36

4-5 Rotor Checking

Note: use the values for the KDA6700TA for both the KDE5000E and KDE5000TA

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4-6 Stator Test Points

CHARGE WINDING PLUG SECONDARY AND SENSING WINDING PLUG

CARBON BRUSH

L1

L2

R1

R2

\

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4-7 Main Stator Winding Check


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4.8 Stator Secondary Winding and Sampling Winding Check


The color of the secondary winding my be blue instead of green

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4.9 Charge Winding Check


4-10 Carbon brush check

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5. KDE5000TA DISPLAY PANEL

5.1 Setting

The digital display panel is preset at the factory. If it becomes necessary to replace the

panel, it will have to be programmed before installation.

(1) Connect the ribbon cable to the new display unit. Be careful not to twist the cable

(2) Remove the back cover of the panel.

(3) Press and hold down the Function “FUNC” and turn the ignition switch ON. Wait 5

seconds to enter the program

(4) Locate the five position DIP switch board and put the DIP switches in the following

position to set the Proper voltage and frequency:

1 2 3 4 5

ON X X X

OFF X X

(5) The three position DIP switch board is factory set but make sure the settings are as

follows:

1 2 3

ON X X

OFF X

Kipor KDE5000E 5000TA Service Manual[1]

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