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KIPOR POWER PRODUCTS CO., LTD GENERATOR SHOP MANUAL KDE5000 KDE5000T Wuxi Kipor Power Co., Ltd. January, 2012 PREFACE This manual covers the construction, function and servicing procedure of the Kipor KDE5000E and KDE5000T North American 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 KM186FAG diesel engine. The current versions of these generators are significantly different from the KDE6700TA and KDE6500E formerly sold in North America. Additionally, the engine has been upgraded for 2012. Contact Kipor for the proper service literature and parts information. 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. WUXI 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. 2 Table of Contents 1. Specifications and Data .................................................................................................................................................... 4 1.1 Specifications ...........................................................................................................................................................4 1.2 KDE5000E Wiring Diagram .......................................................................................................................................5 1.3 KDE5000T Wiring Diagram .......................................................................................................................................6 1.4 Component Identification KDE5000E........................................................................................................................7 1.5 Component Identification KDE5000T........................................................................................................................8 1.6 Control Panel- KDE5000E..........................................................................................................................................9 1.7 Control Panel- KDE5000T..........................................................................................................................................9 1.8 Serial Number Location ..........................................................................................................................................10 2. Service Information ..................................................................................................................................... 11 2.1 The Importance of Proper Servicing .......................................................................................................................11 2.2 Important Safety Precautions .................................................................................................................................11 2.3 Service Rules ..........................................................................................................................................................11 2.4 Electrical Precautions .............................................................................................................................................12 2.5 Generator Service Standards ..................................................................................................................................13 2.6 Fasteners and Torque Values..................................................................................................................................13 2.7 Troubleshooting .....................................................................................................................................................15 3. Generator Testing and Repair ....................................................................................................................... 22 3.1 Start Switch ............................................................................................................................................................22 3.2 Voltmeter ...............................................................................................................................................................23 3.3 Circuit Breaker........................................................................................................................................................23 3.4 Oil Alarm ................................................................................................................................................................24 3.5 Generator...............................................................................................................................................................27 4. Electrical Components ................................................................................................................................. 29 4.1 Receptacle Wiring ..................................................................................................................................................29 4.2 AVR Adjustment .....................................................................................................................................................30 4.3 Battery Charge Regulator .......................................................................................................................................31 4.4 Current Transformer ..............................................................................................................................................31 4.5 Rotor Checking .......................................................................................................................................................33 4.6 Stator Test Points ...................................................................................................................................................34 4.7 Main Stator Winding Check ....................................................................................................................................35 4.8 Secondary and Sampling Winding Check ................................................................................................................36 4.9 Charge Winding Check............................................................................................................................................37 4.10 Carbon Brush Check .............................................................................................................................................37 5. KDE5000T Display Panel ............................................................................................................................... 38 5.1 Setting ....................................................................................................................................................................38 5.2 Connection .............................................................................................................................................................38 5.3 Troubleshooting and Repair ...................................................................................................................................38 3 1. SPECIFICATIONS AND DATA 1.1 Specifications Model KDE5000E KDE5000T 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 3600 3600 Item Rated speed (rpm) Phase Single phase Power factor 1.0 Excitation mode Self-excitation constant voltage (AVR) AC Receptacles 1 120V 15A GFCI, 1 120V 30A ,1 120/240V 30A Structure mode Open frame Coupling method Transmission rigid connection Gross weight lbs. (kg) Overall dimensions LxWxH in. (mm) Enclosed 209 (95) 376 (171) 28.4 x 18.9 x 33.3 (720 x 480 x 845) 35.8 x 20.5 x 29.1 (910 x 520 x 740) Model KDE5000E KDE5000TA KM186FAGE(X) KM186FAGET Item Model Type 4-stroke, single-cylinder, air-cooled, direct injection diesel engine Max output (kW/rpm) 6.6 Bore x stroke in (mm) 3.4 x 2.8 (86 x72) 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 Fuel Electric Diesel Fuel tank volume gal (L) Run time at rated load- hrs Low oil alarm system 3.9 (15) 4.2 (16) 8 8.5 included 4 1-2 KDE5000E wiring diagram 5 1-3 KDE5000T wiring diagram 6 1.4 Component Identification- KDE5000E 7 1.5 Component Identification KDE5000T 8 1.5 Control Panel- KDE5000E 1.5 Control Panel- KDE5000T 9 1.9 Serial number identification and location The generator serial number identifies your particular unit and is important when ordering parts and accessories. A serial number bar code sticker is placed on the generator, on the shipping carton, and on the inside cover of the owner’s manual. Additionally, it is engraved onto a metal serial number tag riveted to the generator. The serial number for the KDE5000T is located on the chassis to the left of the battery and below the oil drain plug. The serial number for the KDE5000E can be found on the left side of the generator frame below the control panel. 10 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 over tightening these screws will strip the threads and ruin the hole. 11 • 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 12 2.5 Generator Service Standards Resistance standard (Ω) Winding Standard value of voltage at No load (VAC) 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 2.6 Fasteners and Torque Values (1) KDE5000E Item Description Inner diameter of screw X length Torque Value Front end cover Hexagonal flange face bolt M8X25 N.M 18 Lbf 13 Rotor through bolt Tighten bolt of fore/back end cover Hexagonal flange face bolt M10X210 50 36 Hexagonal flange face bolt M6X140 10 7 Frame power Hexagonal flange face bolt M10X45 40 29 Earth wire Hexagonal bolt Hexagonal flange face bolt M10 M6X12 40 9 29 7 Electromagnet Cross slotted pan head screw Cross slotted pan head screw M3X5 M4X8 Anti-hunting bracket Hexagonal flange face bolt M8X16 20 15 Oil tank Hexagonal flange face bolt Hexagonal bolt M6X25 M6 9 9 7 7 Decorating plate Hexagonal flange face bolt Hexagonal bolt M6X25 M6 9 9 7 7 Carbon brush Hexagonal flange face bolt M5X20 Rectification block Earth wire Hexagonal flange face bolt Hexagonal flange face bolt M5X20 M5X12 Back cover AVR Hexagonal flange face bolt Hexagonal bolt M5X12 M5 Oil tank assembly Cross slotted pan head screw Cross slotted pan head screw M5X12 M5X8 Nut M6 9 7 Cross slotted pan head screw M6X16 9 7 Hexagonal flange face bolt Hexagonal flange face bolt M6X18 M8X16 9 20 7 15 Hexagonal bolt Hexagonal flange face bolt M8 M6X12 30 9 22 7 Nnt M6 9 7 Butterfly nut M6 9 7 Panel Hydraulic pressure regulator Battery bracket Battery 13 (2) KDE5000TA Item Inner diameter of screw X length Description British standard3/8 tooth bolt Front end cover Torque Value N.m Lbf 16 30 22 Rotor through bolt Tighten bolt of front/back end cover Hexagonal flange face bolt M10X225 50 36 Hexagonal flange face bolt M6X150 10 7 Frame power Hexagonal bolt M8 18 13 Hexagonal bolt M10 50 36 Earth wire Hexagonal flange face bolt M6X8 9 7 Muffler Fixed Hexagonal bolt Hexagonal flange face bolt M8 M8X25 30 20 22 15 Panel Hexagonal flange face bolt Cross slotted pan head screw M6X12 M6X16 9 9 7 7 M6 M5X16 9 7 AVR Nut Hexagonal flange face bolt Carbon brush Hexagonal flange face bolt M5X20 Rectification Earth wire Hexagonal flange face bolt Hexagonal flange face bolt M5X20 M5X12 Back cover of motor Hexagonal flange face bolt M5X12 Oil tank Fixed air cleaner Hexagonal flange face bolt Nut M6X20 M6 9 9 7 7 Charging regulator Hexagonal flange face bolt M8X25 20 15 Bracket Battery bracket Hexagonal flange face bolt Hexagonal flange face bolt M6X12 M8X16 9 20 7 15 Hexagonal bolt Hexagonal flange face bolt M8 M6X12 20 9 15 7 Hexagonal bolt Butterfly nut M6 M6 9 9 7 7 Battery 14 2.7 Troubleshooting Note: The engine shop manual is necessary to troubleshoot, test, and repair many of the faults listed below. 2.7.1 General symptoms and possible cause (1) Diesel engine cannot start or is difficult to start (see engine shop repair manual) Fault: Remedy: Deteriorated diesel fuel Drain the fuel, refill with fresh fuel Fuel is not sufficient Add sufficient fuel Fuel cock is not at the START position. Turn it to START position Fuel delivery line from fuel tank is bent or pipe is clogged Check fuel line 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 in the START position Switch to START Engine oil filter is clogged causing low oil protection Clean or replace oil filter 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, ignition switch, starting relay Starting motor is defective Replace Oil alert switch won’t allow ignition Check and replace as necessary The battery 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 and determine cause of failure. 15 (2) Engine speed is unstable, too high or too low (see engine repair manual) Fault: Remedy: The fuel supply is insufficient Adjust or disassemble and clean Injection pump or injector is defective Check or replace Generator has an overload or short Repair the fault circuit fault Engine governor spring is faulty Replace the springs Valves out of adjustment Adjust valves (3)The generator produces no AC power or the voltage is abnormal or fluctuating. Fault: Gauge panel of generating set Alternator fault Remedy: 1. Circuit breaker fails to function Remove it and check for open circuit. The resistance reading should be “0” 2. The wiring of gauge panel is loose Check for continuity in the wiring harness. 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 if 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 Check resistance value at slip rings. Check defective brushes for wear, weak spring tension 7. Insulation resistance of generator is too low. 16 Check insulation resistance of stator and rotor. Replace stator and rotor as necessary. (3) AVR fault Fault: Remedy: 1. Voltage cannot 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 cannot 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 be 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 of 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) Display panel fault Fault: Remedy: 1. No display on screen. Check 12V power supply of the generator and check wiring. If OK, replace the display unit 2. Displays wrong code. 17 2.8.2 Troubleshooting flow charts (1) Hard starting 18 (2) No AC voltage 19 (3) No Voltage Regulation 20 (4) Generator shutdown 21 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 OFF ON ---------- --------- START ---------- ---------- 4 5 6 7 --------- ---------- ---------- ---------- ---------- . 22 3.2 Voltmeter (KGE5000E) Check generator output with a multimeter. The reading should agree with the voltage meter. 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. 23 3.4 Oil alert PCB and pressure switch 24 25 26 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 0.75 to 0.85 Ω between L1 and L2 and R1 and R2. Check the “zero” on your meter before checking these values. (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. Check the “zero” on your meter before checking these values. (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) replace. (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 KDE5000T, you must remove the air induction hood to get to the harness. (3) Remove 4 - M6 x 175M bolts 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. 27 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 Lbf (10-13 N.m) • The correct spacing is 0.020+/-0.004 in (0.25 +/- 0.1 mm) 28 4. Electrical Component Illustrations 4.1 Receptacle wiring 29 4.2 AVR Adjustment 30 4-3 Battery Charge Regulator 4.4 Current Transformer 31 32 4-5 Rotor Checking Note: use the values for the KDA6700TA for both the KDE5000E and KDE5000TA 33 4-6 Stator Test Points CHARGE WINDING PLUG SECONDARY AND SENSING WINDING PLUG CARBON BRUSH L1 L2 R1 R2 \ 4-7 Main Stator Winding Check Note: use the values for the KDA6700TA for both the KDE5000E and KDE5000TA 35 4.8 Stator Secondary Winding and Sampling Winding Check Note: use the values for the KDA6700TA for both the KDE5000E and KDE5000TA The color of the secondary winding may be blue instead of green 36 4.9 Charge Winding Check Note: use the values for the KDA6700TA for both the KDE5000E and KDE5000TA 4-10 Carbon brush check 37 5. KDE5000T DISPLAY PANEL 5.1 Setting The digital display panel is preset at the factory. 5.2 Connection 1. Unit voltage input 1 2. Unit voltage input 2 3. Current transformer secondary input 1 4. External relay input 1 5. Current transformer secondary input 2 6. External relay input 2 7. Battery negative pole 8. Battery positive pole 5.2 Troubleshooting and Repair There is no field level repair on the display unit. After checking the wiring harness for continuity, the unit must be replaced. 38