KIPOR POWER PRODUCTS CO., LTD.
Preface This manual covers the construction, function and servicing procedure of the KIPOR IG1000. This manual is applicable to all models certified by the California Air Resources Board (CARB) and CETL built in December 2008 and onward. The construction of both generators is identical but CARB model fuel systems use certified materials. Procure the correct parts applicable to your model.
CONTENTS 1. SPECIFICATIONS/WIRING DIAGRAM .................................................................................... 1 1.1 SPECIFICATIONS .............................................................................................................. 1 1.2 WIRING DIAGRAM ............................................................................................................. 3 2. SERVICE INFORMATION .................................................................................................
7. CONTROL PANEL ................................................................................................................ 32 7.1 REMOVAL AND INSTALLATION ....................................................................................... 33 7.2 INSPECTION .................................................................................................................... 33 8. HOUSING/FUEL TANK ......................................................................................................
1. SPECIFICATIONS and WIRING DIAGRAM 1.1 SPECIFICATIONS Dimensions and weights Model IG1000 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) 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.
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 Voltage variation rate 1.0 Momentary 10%max. Average 1.5%max. Average time 3 sec. max. Voltage stability ±1% Frequency variation rate Momentary 1%max. Average 1%max. Average time 1 sec. max. Frequency stability ±0.1% Insulation resistance 10MΩ min.
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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. 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.
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.
• 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.
2.6 Maintenance standards Part Item Engine Maximum speed without load Cylinder Sleeve I.D. Skirt O.D Piston Pin bore I.D. Piston pin O.D Height Ring side clearance 1st ring Ring end clearance Width Height Ring side clearance Piston ring 2nd ring Ring end clearance Width Height Ring side clearance Oil ring Ring end clearance Width Small end I.D Connecting rod Big end I.D Crankshaft Valves Crank pin O.D. Valve clearance Stem O.D.
Exhaust Valve spring Guide I.D. IN/EX Free length IN/EX Cam wheel Cam height O.D Camshaft Camshaft bearing I.D. I.D(Rocker arm) Rocker arm O.D.(Rocker arm shaft) I.D.(Rocker arm shaft bearing) Spark plug Ignition coil Gap Primary side Second side Resistance Air gap Pulse coil (Trigger) Resistance 3.965—3.980 mm 0.1557-0.1562 in 3.955—3.970 mm 0.1575-0.1579 in 4.000—4.012 mm 0.925 in 23.5 mm 1.101-1.103 in 27.97-28.03 mm 0.1963-0.1967 in 4.988-4.996 mm 0.1976-0.1988 in 5.02-5.05 mm 0.1575-0.
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.
3.2 Hard starting No fuel Check the fuel level in the tank. Add fuel and restart the engine. Sufficient fuel Loosen the drain screw and check whether fuel reached the float chamber and the oil level. Abnormal Check the fuel lines for blockage. Normal Dry Remove the spark plug and check for wet or fouled electrode. Check for blockage in the carburetor intake port and nozzle. Clean the electrode and restart, Ensure the choke is not closed. If flooding is severe, check the carburetor float valve.
C. Ignition system ■ Fill in oil to the demanded level. ■ Use the genuine spark plug A7RTC. ■ 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.
3.2 Hard Starting Continued Measure the spark plug gap and perform the spark plug test. Gap: 024-028 in (0.6—0.7mm) No spark Perform the spark test again using a Good spark new spark plug Replace the spark plug No spark Remove the control panel. Perform Good spark spark test with a new ignition module.
3.3 Engine oil level is low, but engine does not stop. (Defective oil switch) Drain out oil completely, disconnect alarm No continuity connection wire, and check the continuity Replace the oil level alarm between alarm outlet terminal and ground. Continuity Reset the alarm connection wire, disconnect No continuity Repair or replace the wire ignition module and check the continuity harnesses between the plug orange wire and ground. Continuity Ignition module fault: replace module. 3.
3.
3.7 Smart system doesn’t work with zero load or engine speed doesn’t increase with Smart system on and load connected.
3.9 No DC output Check the engine speed Normal Abnormal Perform the throttle control system troubleshooting Abnormal Check the DC receptacle Replace the DC receptacle Normal Check the 5 amp fuse Normal Check the rectifier Abnormal Abnormal Replace the fuse Replace the rectifier Normal Measure the resistance between the two blue wires on the rectifier. Resistance: 0.16-0.
4. Maintenance 4.1 Maintenance schedule Regular service period Item perform at every indicated month or operating hour interval, Each use whichever comes first Engine Oil Air filter Check Every 3 Every 6 Every month or months or months or year or 20 Hrs. 50Hrs. 100 Hrs. 300 Hrs.
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.
2. Stop engine, disconnect oil alarm connector, check the connector conduction, no conduct is normal. 3. Drain out the oil inside engine and 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.
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.
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 A7RTC 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.
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.
4) Insert a feeler gauge between the rocker arm and the valve and measure the 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.
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.
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.
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.
5. Muffler Caution ■ Muffler removal/installation must be performed with the engine cold.
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.
6.
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.
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 3：45~55Ω Between 2 and 4：45~55Ω Replace the stepping motor if the resistance excesses the above range.
7. Control panel 7.
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.
● Engine switch Check the continuity of connector, there should be continuity when the micro switch is depressed. ● Rectifier Measure the on or off (positive pressure fall) of rectifier with control potentiometer measurement should accord with the standard as shown in the chart.
8. Housing / Fuel tank 8.
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.
9. Recoil starter/ Air conduct cover/ Ignition coil/ Air conduct plate 9.
9.
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.
(2) Smear lubrication grease on the starter outer shell claw, install the starter reel. Revolve the reel anticlockwise to hang the spring inner hook on the starter outer shell claw. (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.
(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.
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—1.3Ω ● 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.
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. Resistance 0.50-0.70Ω (2) Outer charging winding Measure the resistance between the two blue terminals. Resistance 0.12-0.15Ω (3) Sub winding Measure the resistance between the two sub winding terminals. Resistance White-white 0.25~0.35Ω (4) Main winding Measure the resistance among the terminals of the main winding.
(5) Trigger Attach the two test leads to the trigger and measure the resistance. Trigger resistance 80-130 Ω 10.3 Trigger adjustment Adjust the clearance between trigger and the projection part of rotor. Trigger clearance 0.0197-0.0275 in (0.50-0.75 mm) Insert a feeler gauge between the trigger and the projection part of the rotor; loosen the trigger fixed plate bolt to adjust the clearance slightly.
11. Cylinder cover/ Rocker arm 11.
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 in 4.
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.
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.
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 gasket material. 4. Screw on the crankcase cover bolts slowly and tighten to the prescribed torque. 12.
● Cam height Standard in (mm) 1.101-1.103 (27.97-28.03) Service limit in (mm) 1.062 (26.97) ● Cam inner diameter Standard in (mm) 0.1976-0.1988 (5.02-5.05) Service limit in (mm) 0.2008 (5.10) ● Camshaft outer diameter, tappet shaft outer diameter Standard in (mm) 0.1963-0.1967 (4.988-4.996) Service limit in (mm) 0.1949 (4.
●Valve tappet inner diameter Standard in (mm) Service limit in (mm) 0.1968-0.1975 (5.000~5.018) 0.1988 (5.
13. Crankshaft/ Piston 13.
13.2 Piston Assembly of piston ring Caution ● Set the manufacture label up. ● Pay careful attention not to mix the location of the 1st ring and 2nd ring. ● Check the piston ring for flexibility after installation. ● Stagger each piston ring opening 120°apart.
● 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.
● 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) Intake/Exhaust valve 0.1575-0.1579 (4.000-4.012) Service limit in (mm) 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.
● 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 cylinder Standard in (mm) Service limit in (mm) 0.0008-0.0024 (0.02-0.06) .0047 (0.
● 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.
● Piston ring height Standard in (mm) Service limit in (mm) st The 1 ring The 2 nd ring 0.0030-0.031 (0.77-0.79) 0.028 (0.70) 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.
● 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 (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.
● 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.
● 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.
●Camshaft bearing inner diameter, tappet shaft bearing inner diameter (cylinder block) Service limit in Standard in mm） 0.1976~0.1988 (5.02~5.05) (mm) 0.2008 (5.10) ●Camshaft bearing inner diameter, tappet shaft bearing inner diameter (gear case cover) Service limit in Standard in mm） 0.1976~0.1988 (5.02~5.05) (mm) 0.2008 (5.
● 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.
