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DIESEL

GENERATOR
WUXI KIPOR POWER CO., LTD.

OPEN FRAME:

SINGLE PHASE: K DE7000E/EA


K DE11000E/EA
THREE PHASES: K DE8000E3/EA3
K DE12000E3/EA3
SILENT:

SINGLE PHASE: K DE7000T/TA


K DE11000T/TA
THREE PHASES: K DE8000T3/TA3
K DE12000T3/TA3

Remark

BeiYu electric appliance

D50/1620 25A

1
Quantity
Breaker
Name

Material

PLY-MB-D

PLY-MB3-ATS-C
1
Digital module

PLY-MB-ATS-S1
1

Thank you for purchasing Kipor diesel generators.

1
Digital display

Relay

ATS module

A26-40-00

HFV4 12V 20A


3

2
AC contactor

Throttle electric magnet

BX201C
2
Fuse (extend 6X30

10A

BX2041C
1
Four line fuse box

20A

10A
Fuse link

Fuse link

Exciting winding

Generating/Sampling winding

Emergency stop button

Flywheel generator winding

50/5mA

LAY37-11ZS
1

1
Current transformer

Automatic voltage adjustor

35Ah

6-QW-36 12V 36Ah 310A

Battery

Charging adjustor

JK427

220V/15V 40A

Transformer

Ignition switch

PREFACE

This operation manual will tell you how to operate and service your KIPOR
generator set correctly. Please read this manual before using the generator set
to ensure the proper operation.Follow the instructions to keep your generator set
in the best working condition and extend the life of it .If you have any commends
or problem, please contact with our sales company or the authorized agent.
This manual deals with the general items of the KIPOR diesel generation set.
However, the manual may vary with the development of the products in the future.
Please give special attentions to warnings and cautions.

WARNING

Indicates that the severe personal injury even death will


result if the instructions are not followed.

CAUTION

Indicates that the serious personal injury or equipment


damage will result if the instructions are not followed.

KIPOR diesel generator set will meet your requirement if you operate it according
to the manual instruction. Otherwise serious personal injury and equipment
damage will result.

QF
Code name
1

K1,K2,K3
5

KM2

YV

KM1
6

FU4
FU1
8

FU2
9

FU3

BX2011C

BX2011C

11

10

W1

15

W2

SB

W3

16

12

L1

14

AVR (Digital)
18

17

13

GB
20

TC

19

SA
22

21

24

23

So, KIPOR reconfirms that you must to read and understand this manual before
operating the generator set.

Three phases
KDE8000EA3/TA3
KDE12000EA3/TA3

ON/OFF Table for electric starting key


OFF
ON
START

Orange blue20#
KM1
Brown Blue20# KM2

Red20#
DC charging output

Yellow green20#
KM1

Generator supplying output


ATS
controlling module

Brown white20# TC
~15V Blue white20# AC charging input

~220V

Red white20#
Black white20#

Citizen AC input

Black20#

Citizen input

Green18#

Green10#

Red10#

Red10#

L1

Black10#

L1

Yellow10#

KM2
Yellow10#

Green10#

Green10#

Green10#

Red10#

Red10#

Red10#

Black10#

Black10#

Black10#

L1

Yellow10#

U
V

Controlling signal

F+50HZ
F- 60H
6 3 Yellow18#
7 4

Yellow10#

Green10#

Black10#

N
W2 Red18#

KM1

Yellow10#

Generator supplying output Purple black20#

Generator AC signal input

Red20#
U

Purple gray20#
Pink blue20#
KM2
Yellow blue20# KM1

W
N
E

Yellow20#

Green20#
Red20#
Black20#
Red black20#

Voltage sample

Blue18#
Red18# Fu1
Red16#

FU3

Blue20#

Red18

Blue20#

K2
Brown16#
YV

A0

Yellow16#
K1

Operation signal output


Orange18# ON
+12V
SA

Fu2

White18# +12V

K3
Red14# Green14#
Starting electric magnet

Adjustor

W3

Battery

Green16#
K2

Jerk signal input

Purple20#

Digital panel display

Yellow black20#
SB

Current sample

Brown black20#

Gray18#
ST
Starting signal output

Pink 20#
K3
Starting
motor

Yellow green18#
Purple orange18#

Digital panel
display
Starting signal input

OV
AC voltage
Low oil sample for flywheel
pressure
switch

ATS options

Remark

BeiYu electric appliance

D50/1620 25A

1
Quantity
Breaker
Name
QF
Code name
1

Material

PLY-MB-D

PLY-MB-ATS-C
1
Digital module
2

PLY-MB-ATS-S2

Digital display
3

Relay

ATS module

A26-40-00

HFV4 12V 20A

K1,K2,K3
5

1
Throttle electric magnet

AC contactor
KM2

YV

KM1
6

BX201C
2
10A
Fuse (extend 6X30
FU4
FU1
8

BX2041C
1
Four line fuse box
FU2
9

FU3

20A

10A
Fuse link

Fuse link

BX2011C

BX2011C

11

10

W1
12

Exciting winding

Generating/Sampling winding

W2

Secondary winding
W3
14

13

Emergency stop button

Flywheel generator winding

SB

W4
15

50/5mA

LAY37-11ZS
1

16

Current transformer
L1

Automatic voltage adjustor


AVR (Digital)
18

17

35Ah

6-QW-36 12V 36Ah 310A


1
Battery

1
Charging adjustor

GB
20

19

JK427

220V/15V 40A
1
TC
21

Transformer

Honda or European style

2
Receptacle

SA

Ignition switch

X1 X2

22

24

23

Safety Information
WARING
1. TO PREVENT THE FIRE
Never add fuel to the fuel tank while the engine is running.
Wipe off the overflowed fuel with a clean cloth. Keep explosives and other
flammable products away from the generator set.
To prevent the fire and to provide adequate ventilation, keep the generator set
at least one meter away from buildings and other equipment during operation.
Operate the generator set on a level surface.
Do not put the generator set indoors while the engine is hot.
2. TO PREVENT FROM INHALING THE EXHAUST
Exhaust gas contains poisonous carbon monoxide, which is harmful to the
health. Never use the generator set at the confined places or poor ventilated
locations. If it's necessary to run the generator set indoors, be sure to provide
the adequate ventilation.
3.BE CARE NOT TO BE SCALDED
The muffler and the engine body are very hot while the engine is running or
just after running, do not touch these parts to prevent from being scalded.
4. ELECTRIC SHOCKS, SHORT CIRCUITS
To avoid electric shocks or short circuits, do not touch the generator set when
your hands are wet. This generator set is not waterproof, so it should not be
used in a place exposed to rain snow or water sprays. Use the generator set in
a wet place can cause short circuits and electric shocks during operation.
The generator set should be grounded to prevent electrical shocks from faulty
appliances. Connect a length of heavy wires between the generator sets
ground terminal and an external ground source.
Do not hook up tools or other apparatus to generator set before it has been
started. If equipment is attached, generator starting may cause sudden
movements of the equipment and result in injuries and accidents. Be sure to
disconnect any apparatus from the generator set or prior to starting.

KDE11000E/EA Double voltage output

CAUTION

ON/OFF Table for electric starting key

Most appliance motors require more than their rated


wattage for start-up.
Do not exceed the specified current limit of any socket.
Do not connect the generator set to a household
circuit. This could cause damage to the generator set
and to electrical appliances in the house.

OFF
ON
START

5. WHEN CHARGING THE BATTERY

Red20#

ATS options

Yellow green20#

DC charging output
KM1
Orange white20# TC

Battery electrolyte contains sulfuric acid. Protect your eyes, skin and clothing.
In case of contact, flush thoroughly with water and get prompt medical attention,
especially if your eyes are affected.
Batteries generate hydrogen gas, which can be highly explosive. Do not smoke
or allow flames or sparks near a battery, especially during charging.
Charge the battery in a fully ventilated place.

Brown blue20#KM2Orange blue20#

Red white20#
Black white 20#

Citizen AC input

ATS Yellow blue20#KM1Pink blue20# KM2


controlling
Generator supplying output Purple black20#
module

Black 20#
Generator AC signal input

Red 20#
Red10#

N
Citizen input~240V
U

Red10#

Black10#

KM1

Black10#

Red10#

Output connection column


Red12#

Red10#

X1
120V

W1

Red18#

F+50H
Green18# F-60

Blue10#

W2

6
7

L1

3 Yellow
18#

X3
240V

Blue12#

Brown10#

X2

KM2

Controlling
signal

120V

W1

Black10#

Black10#

Black12#
Yellow green12#

Yellow green12#

Voltage sample

Blue white20#

Current sample

Brown white20#
Blue black20#
Brown black20#
SB

Purple20#

Jerk signal input


Green18# Operation signal output
ON
Orange18#
+12V

Blue18#

Red18# FU1 White18#

SA
FU3

Blue20#

Red16#

Red18# FU2

A0
K1

YV

Starting
electric
magnet

K1

Blue20#
K2

K3
Red14# Green14#

Yellow16#

Green16#
W4

Gray18#

K3

M Starting
motor

Yellow green18#
Purple orange18#

ST

Digital
panel
display
AC voltage
sample for Starting signal output
Low oil
flywheel
pressure OV
switch

Brown20#

Pink20#

Battery
Adjustor

Digital
panel
controller

White18#
+12V
Starting signal output

Blue20#

K2
Brown16#

KM1

Citizen supplying output Purple gray20#

~15V Blue white AC charging input

~220V

Battery

AVR (Digital)
L1

18
17

FU1

Digital display
Digital module
Breaker
Name

3
2
1

Relay

AC contactor
ATS module

QF
Code name

10A

Throttle electric magnet

Fuse (extend 6X30

Four line fuse box

Fuse link

Exciting winding

Secondary winding

K1,K2,K3

KM2

KM1

YV

FU4

FU3

FU2

Fuse link

BX2011C
BX2011C

W1

12
11

W2

10

Generating/Sampling winding

W3

14
13

Emergency stop button

15
Flywheel generator winding

SB
W4

16

Current transformer

Automatic voltage adjustor

Charging adjustor

Transformer

GB

TC

21

Receptacle
Ignition switch

20

SA

19

X1 X2

22

24
23

1
Quantity

Material

D50/1620 25A

PLY-MB-ATS-C

PLY-MB-D

PLY-MB-ATS-S1

HFV4 12V 20A

A26-40-00

BX201C

BX2041C

20A

10A

LAY37-11ZS

50/5mA

6-QW-36 12V 36Ah 310A

35Ah

220V/15V 40A

JK427

Honda or European style

Remark

BeiYu electric appliance

CONTENTS

1.Main Technical Specifications and Data


1

2.Parts Name
3

3.Preparation for Starting


6

4.Start the Generator Set


9

5.Operate the Generator Set


11

6.Load
12

7.Stop the Generator Set


15

8.Periodic Checks and Service


16

9.Long-term Storage
19

10.Troubleshooting and Remedy


20

11.Electric diagram and wiring diagram


21

KDE11000E/EA single phase

ON/OFF Table for electric starting key


OFF
ON
START

Red 20#

ATS options

Yellow green20#

DC charging output
KM1 Orange blue20# KM2

Brown blue20#
Purple gray20#

KM2 Pink blue20# KM1

Citizen supplying
output

Yellow blue20#
Generator
Purple black20# supplying output

KM1 Orangewhite20# TC
~220V

~15V Blue white20#

ATS
controlling
module

AC charging input

Red white20#
Black white20#

Citizen AC input

Black20#
Red20#

Citizen
input

Red10#

~
M

Black10#

KM1

Black10#

Controlling signal

Red10#

Red 18#
F+
W2
50Hz
Green18#F- 60 3

Red10#

Red10#

KM2
W1

6
4 Yellow18#
7

Generator AC signal
Red10#

Black10#

Black10#

Sampling
winding

Yellow green12#

Red20#
Voltage sample

Blac 20#
Gray20#

Current sample

Gray20#
Purple20#

Blue18#

Jerk signal input

Green18#

Operation signal output ON

Red 18# FU1 White18#

Orange18#

ON
+12V

FU3
Red16#

Red 18# FU2

Blue20#
Blue20#

K2

K1

YV
Blue20#
K2

White18#
+12V

Yellow16#

A0

Brown16#

Digital panel display

SB

Red 14# K3 Green14#

K1
Green16#
W4
Battery
Adjustor

Starting
electric
magnet

Starting signal
Gray18# output
ST
Brown20#

Pink20#
K3

Starting
motor
Yellow green18#
Purple orange18#

AC voltage
Low oil
sample
pressure 0V for flywheel
switch

Starting signal
input

Model

FU1

FU4

10A

6.8
120/240
51.7/25.8

6
115/230
48.7/24.3
3000

KVA
V
A
r/min

Max. output
Rated voltage

NOTE: A is digital panel

stroke mm

KD2V86F

Without

10.3/3000

Dry weight(kg)

Structure type

Starting system

W H(mm)

Continous running time h

9.5

T/TA:220
12 V Electric starter

E/EA:155

10.5

3600

79.2/39.6

120/240

6.5

11.3/3600

T/TA:265
12 V Electric starter

E/EA:185

T/TA 1136 650 860 E/EA 930 620 690

E/EA:Open frame T/TA:Slient

T/TA 1056 630 820 E/EA 920 560 645

340
25

25

L-ECD grade 15W30 or 15W40

Diesel:0#(summer),-10#(winter),-35#(cold)

19 : 1

7.2/3600

Fuel tank capacity L

11

6.6/3000

0.836

20 : 1

86 72

0.610

78 62

340

SET Overall dimension: L

60
9.5

Two cylinder V style air cooled four stroke direct injection Two cylinder V style air cooled four stroke direct injection

KD2V78F

Remark

Material

KDE11000T/TA

BeiYu electric appliance

D50/1620 25A

Fuel comsuption g/KW.h

Lube oil brand

Fuel type

Rated power [kW/(r/min)]

Eng- Displacement L
ine Compression ratio

Cylinder NO.-bore

Engine Type

Engine Model

Working type

12 hours continuous running

2
12V/8.3A

1.0

Pole number
DC output

3000

73.9/36.9

115/230

9.5

8.5

50

KDE11000E/EA

1
Quantity

Single phase, three loops / Self-excitation and constant voltage(AVR

Insulation Grade

Genr- Phase NO./Excitation mode


ator Power factor cos

Rated rotation speed

3600

6.2

5.6
kVA

Rated output

Rated current

60

50

KDE7000T/TA

Breaker
Name

Hz

QF
Code name

Rated frequency

PLY-MB-D
1

PLY-50MB-2C
Digital module

HFV4 12V 20A

A26-40-00

BX201C

BX2041C

20A

10A

50/5mA

PLY-MB-ATS-S1

KDE7000E/EA

35Ah
6-QW-36 12V 36Ah 310A

Digital display

JK427
220V/15V 40A

Relay

AC contactor

Throttle electric magnet

Fuse (extend 6X30

Four line fuse box

Fuse link

Exciting winding

Secondary winding

Flywheel generator winding

User charging winding

Current transformer

DC12V 8.3A
Honda or European style

K1,K2,K3

KM2

KM1

YV

FU3

W1

12

FU2

W2

13

Fuse link

W3

BX2011C

W4

15
14

BX2011C

W5

16

11

L1

10

Generating/Sampling winding

AVR (Digital)

18
17

Automatic voltage adjustor

Battery

Transformer
Charging adjustor

Ignition switch

GB

TC

Receptacle

20

SA

22
21

DC receptacle

19

X3
X1 X2 X3

24
23

1.MAIN TECHNICAL SPECIFICATINS AND DATA

Single-phase diesel generator

KVA

KW

kVA

Hz

NOTE: A is digital panel


cos

Structure type

Starting system

Dry weight(kg)

Continous running time h


SET Overall dimension: L W H(mm)

Fuel tank capacity L

Fuel comsuption g/KW.h

Lube oil brand

Fuel type

Rated power [kW/(r/min)]

Cylinder NO.-bore stroke mm


Eng- Displacement L
ine
Compression ratio

KD2V78F

12V/8.3A

3000

13.7

400/230

10.5

7.6

9.5

50

12 hours continuous running

0.8(lag)

KD2V86F

3600

14.6

416/240

11.5

8.4

10.5

60

KDE12000T3/TA3

Without

KDE12000E3/EA3

Three phase four line,"Y" connection

3600

10

416/240

7.9

5.75

7.2

60

KDE8000T3/TA3

25

340

10.3/3000

10.5

L-ECD

12 V Electric starter
E3/EA3:Open frame T3/TA3:Slient

E3/EA3:155 T3/TA3:220

25

340

19 : 1

0.836

86 72

6.5

11.3/3600

12 V Electric starter

T3/TA3 1056 630 820 E3/EA3 920 560 645


E3/EA3:185 T3/TA3:265

15W30 or 15W40

Diesel:0#(summer),-10#(winter),-35#(cold)

7.2/3600

T3/TA3 1056 630 820 E3/EA3 920 560 645

11

6.6/3000

20 : 1

0.610

78 62

Two cylinder V style air cooled four stroke direct injection Two cylinder V style air cooled four stroke direct injection

3000

9.5

400/230

7.2

5.3

6.6

60

KDE8000E3/EA3

Engine Type

Engine Model

Working type

DC output

Pole number

Insulation Grade

Power factor

Rated rotation speed


r/min
Genrator Phase NO./Excitation mode

Rated current

Rated voltage

Max. output

Rated output

Rated frequency

Model

Three-Phase diesel generator


KDE 7000E/EA double-voltage
optional output

Yellow16#

Blue18#

Blue18#

Red16#

Brown16#

Blue20 #

Blue16#

Yellow18#

Yellow18#

Blue20 #
Yellow18#

Adjustor

ON/OFF Table for electric starting key


OFF

START

ON

Red16#

Blue16#
Black16#

Yellow16#

Red18#
Red10#
Brown10#

Green18#
Red10#
Red10#
Blue10#

Sampling
winding

Brown10#

Black10#
Black10#

Yellow green20#

Black10#

Red white20#

Red green20#

Red blue20#

Blue white20#

Black white20#

Brown white20#

Red black 20#

Blue black20#

Brown black20#

Blue18 #

Red18#

Blue20 #
Red18#

Starting
electric
magnet

Starting
motor

White18#

Red14# Green14#

Pink20#

Low oil
pressure
switch

Digital
panel
controller

Black20#
Operation signal output

White18#
Orange18#

+20V

Gray18# Starting signal output

Green16#
Brown20#
Digital
panel
display

Battery
AC voltage
sample
for flywheel

W4
W3
W2
W1
BX2011C
BX2011C
FU2
FU1

15
14
13
12
11
10
9
8
FU4

Breaker
Name

Digital module

2
QF
Code name

ATS module
Digital display

Relay

AC contactor

3
1

10A

Throttle electric magnet

Fuse (extend 6X30

Four line fuse box

Fuse link

Exciting winding

Secondary winding

Flywheel generator winding

User charging winding

K1,K2,K3

KM2

KM1

YV

Fuse link

W5

16

FU3

Generating/Sampling winding

L1

BX201C
2

BeiYu electric appliance

Remark

PLY-MB-D
PLY-MB-ATS-C
D50/1620 25A
Material

1
Quantity

1
1

PLY-MB-ATS-S1

3
1

A26-40-00
HFV4 12V 20A

BX2041C
1

20A

10A

50/5mA

Automatic voltage adjustor

AVR (Digital)

18
17
1

Current transformer

35Ah
6-QW-36 12V 36Ah 310A

Battery

JK427
220V/15V 40A

Charging adjustor

Transformer

Ignition switch

GB

TC

DC12V 8.3A
Honda or European style

20

SA

22
21

Receptacle

DC receptacle

19

X3
X1 X2

24
23

2. PARTS NAME

2.1 Parts name (E/EA, E3/A3 Type)


Oil filler cap

Oil dipstik

Muffler
Oil drain plug

Fuel tank

Black10#

Adjustor

Green16#
Battery

Blue20# Yellow16#

Blue20#

Blue20#

Brown16#

W3Blue18#
Yellow18#
Blue18#
Sampling
winding

W2Red 18#
Green18#

Citizen
input

Red10#

Purple orange18#

Yellow green18#

Starting
motor

Starting
electric
magnet

Red 14# K3 Green14#

Red 18# FU2

Voltage
sample

Red10#

Pink20#

Starting signal
input

Digital
panel
display

Controlling
signal

AC voltage
Low oil
sample
pressure for flywheel
switch

Brown20#

Gray18# Starting signal


output

White18#

Orange18#

Current
sample
Operation signal output ON

Gray20#
Gray20#

Black red20#

Red black 20#

Yellow green12#

Black10#

Red10#

Black10#

Red 18# FU1 White18#

Blue18#

Black10#

KM2

KM1
Red10#

ATS
controlling
module

Generator AC signal

Citizen AC input

Red10#

Red black 20#

Yellow white20#

Red white20#

AC charging input
Blue white20#

Lifting eye

KM2 Pink blue20# KM1 Yellow blue20#


Generator
Purple black20# supplying output
Orange
KM1 white20# TC

ATS options

Fuse

Red16#

Cooling air outlet


DC charging output

Exhaust
vent
KM1 Orange blue20# KM2 Brown blue20#
Citizen supplying
Purple gray20# output

Fuel filler cap

Emergencg
stop button

Red 20#

Engine starter switch

Yellow green20#

2.1 Parts name


T/TA, T3/TA3 type

11. ELECTRIC SCHEMATIC DIAGRAM AND ELECTRIC WIRING DIAGRAM


KDE7000E/EA single phase
OFF and ON table for electric starting key
OFF

START

ON

AC Output

2.2 Control panel

10. TROUBLESHOOTING

Fault

Troubleshooting

Engine can't start or fuel is not sufficient Refill


The switch is not at START position

Turn it to START position

The fuel injection pump and nozzle don't


deliver the fuel or deliver insufficient fuel

Check the engine oil level

Remove the nozzle and repair it at test table

The specified oil level should be


between the upper level and lower level

The nozzle is dirty

Clean the nozzle

The battery has no electricity

Charge or replace it

Insufficient oil and low rotation speed

Adjust the throttle bolt and fill in oil

EA type panel

Generator sets can't work and the main switch is off Turn on the main switch
The carton brush already worn

Replace the carton brush

Bad receptacle contact

Adjust the receptacle

TA type panel

3. PREPARATION FOR STARTING

9. LONG-TERM STORAGE

3.1 Selection and using of the fuel


Selection of fuel
Only use the light diesel, which is most suitable for the engine.
Keep dust and water out of the fuel
When filling the fuel tank from drums, make sure that no dust or water is mixed
in the fuel. Otherwise the serious fuel injection pump and nozzle problems will
result.
Do not overfill
Overfilling is very dangerous. Do not fill the tank beyond the top of the red plug
inside the fuel filter.

Do the following preparations for long-term


storage:
1.Run the generator for 3 minutes and then
stop.
2.If the generator is still hot after stop
running, please drain out the original oil and
fill in fresh oil.
3.Screw off the bolt of cylinder cover, fill in
2CC oil and tighten the bolt.
4.Clean the generator and store it in dry
area.

WARNING
Refuel in a well-ventilated area with the engine stopped.
Do not smoke or allow flames or sparks in the area where the engine is refueled or where the fuel stored.
Do not overfill the tank, make sure the filler cap is securely closed after
refueling.
Be careful not to spill fuel when refueling. If any fuel is spilled, make sure
the area is dry before starting the engine
3.2 Check and refill the oil

WARNING
Always check the oil level with the generator set on a level surface before
staring and refill if necessary.
The engine may be damaged if operated with insufficient oil, it is also
dangerous to refill too engine oil as sudden increase in engine speed may be
caused by its combustion.
CAUTION:
KIPOR KDE series generator set are equipped with low oil alarm system. This
system will stop the engine automatically when the oil level falls below the lower
level. This prevents accidents such as bearing seizures, etc.

Drain oil bolt

1. Drain out the fuel from the fuel tank.


2. Drain out the fuel from the fuel tank.
Screw off the small screw of the fuel cock and pull out the filter from the filler
port.
3. Wash the filter thoroughly with diesel fuel.
Loosen the fastening nut, bottom cover and delivery discs for cleaning the
deposit carbon.
8.5 Tighten cylinder head bolt
Tightening the cylinder head bolt requires a special tool. Do not try yourself.
Contact with KIPOR agent.
8.6 Check the injection nozzle and fuel injection pump
1. Adjust the clearance of the intake/exhaust valves.
2. Grind the intake/exhaust valves.
3. Replace the piston ring

WARNING
Do not perform the injection nozzle test near an open fire or any other kind of
fire. The fuel spray may ignite. Do not expose bare skin to the fuel spray. The
fuel may penetrate the skin and cause injury to the body. Always keep your
body away from the nozzle.
8.7 Check and refill the battery electrolyte and charge the battery
The diesel uses a 12V battery. Battery electrolyte will be lost through continuous
charging and discharging.
Before starting, check for physical damage to the battery and also the electrolyte
levels, and refill the distilled water till to the upper lever if necessary. When actual
damage is discovered, replace the battery.
Check the battery electrolyte monthly.

Select the most applicable oil


It is very important to select the applicable oil in order to keep up the
performance and life of the generator set. If inferior oil is used, or if your oil is
not replaced periodically, the risk of piston seizure, piston ring sticking and
accelerated wear of the cylinder liner, bearing and other moving components
will increase significantly. So the generator set life will be shortened. KIPOR
recommends CC/CD oil classified by API. Choose the applicable viscosity oil
according to the local ambient temperature.

3.3 Check the air cleaner


1.Screw off the wing nut, remove the air cleaner
cover and take out the element.

Air cleaner

CAUTION:
Do not wash the element with detergent.
Replace the element when its output decrease
or a bad exhaust color is noticed.
Never run the generator set without the element, otherwise the rapid engine wear will result.
Air cleaner cover

2. Reattach the air clearer cover and screw on the


wing nut.

WARNING
The battery electrolyte contains sulfuric acid. Protect your eyes, skin and
clothing. In case of contact, flush thoroughly with water and get prompt medical
attention, especially if your eyes are affected.
The battery exhaust hydrogen gas, which can be highly explosive. Do not
smoke or allow flames or sparks near the battery, especially during charging.

Element

8.1 Replace engine oil


Remove the oil filler cap. Remove the drain
plug and drain the old oil while the engine
is still warm. The plug is located on the
bottom of the cylinder block. Tighten the
drain plug and refill with the recommended
oil.

3.4 Check the generator set


1. Turn off the main switch and any other loads.
WARNING:
Be sure to turn off the main switch before
starting.
The generator set should be earthed to prevent
electric shocks.

Oil gauge Drain oil bolt

AC output receptacle

8.2 Clean the engine oil filter

Cleaning time Every 6 months or 500 hours


Replace if necessary
WARNING:
The generator set should be earthed to prevent
electric shocks.

Ground terminal

Oil filter

Cleaning time Every 6 months or 500 hours

Ground terminal

2. Use dual voltage type generator sets


Be sure to place the changeover switch in the correct position for the rated
voltage of the working instrument.

Filter element

CAUTION
Never run the engine without the element or with a defective element.

CAUTION:
Before starting the engine, be sure to turn the switches of the control panel
(lighting apparatus, motor, etc.) to their "OFF" position. If the switches are not
in the "OFF" position, the sudden application of load when the engine is started
could be very dangerous.

8.4 Clean and replace fuel oil filter


The fuel oil filter also has to be cleaned regularly to insure maximum engine output.

Clean time

Every 6 months or 500 hrs

Replace time

Every year or 1000 hrs

8. PERIODIC CHECK AND SERVICE


Periodic check and service are very important for keeping the engine in good
condition and durable. The chart below indicates what checks to make and when
to make them.

WARNING
Shut off the engine before performing any service. If the engine must be run, make
sure the area is well ventilated. The exhaust contains poisonous carbon monoxide
gas.
After the generating set has been used, clean it immediately with a cloth to prevent

8.1Maintainace table:
Interals
Item

Every
month

First month Third month Sixth month Every year


or
or
or
or
500 Hrs
100 Hrs
20 Hrs
1000 Hrs

Check and refill oil


Drain out fuel oil
Check and refill engine oil
Check for oil leakage
Tighten the
cylinder head bolts

Check and tighten fastening parts


Replace engine oil

(First time)

(After second time)


(Replace if
necessary)

Clean engine oil filter


Replace air cleaner element

shorter maintainance period for dusty area

3.5How to open the cabinet door and


covers of the silent generator set.
1. Turn the lever clockwise and open the
cabinet door for daily inspection.
2. Loosen the bolt of the air cleaner check
port cover to check the air cleaner.
3. Screw off the wing nut to open the cover
of nozzle, then check the nozzle.

3.6 Break-in period operation


The first 20hrs are the break-in period of the engine, the operator must obey to
following items:
Warm up the engine 5 minutes after the initial starting. Run the engine at low
speed and zero load before the engine becomes warm.
Avoid applying any heavy loads during the break-in period. KIPOR
recommends to run the engine at 3000r/min with 50% load in break-in period.
Replace the oil on time.
Replace the oil while the engine is warm after 20-hours-running, the old oil will
be drained out completely.
Approx.one month or 20hours

Every 3 months or 100 hours

Replace

Clear fuse element


Check fuel injection pump
Check nozzle
Check fuel pipe

4. START THE GENERATOR SET

Adjust clearance of intake/exhaust valves


Grind intake/exhaust valves

WARNING

Replace piston ring


Check battery electrolyte

Every month

Check carbon brush and slip ring


Check insulation resistance
Note:

The generating set has been stored more than 10days

indicates that special tools are required, please contact with KIPOR agent.

DO not hook up tools or other apparatus to the generator set before


starting.

WARNING
Please tighten the screw on the cylinder to prevent any rainwater&dust,which
may cause wearing of inner parts as well as break-downs

7. STOP THE GENERATOR SET


7.1 Stop the generator set normally
1. Cut off the load

4-1 Recoil starting


1.Start the engine according to the following
procedures:
Open the fuel cock.
Set the engine speed lever at the RUN position.
Remove hands from the startor switch after the
engine started , and the switch will return to the
RUN position automatically.
It will spend 10s to start, if the engine doesn't
start after 10s please wait 15s to restart it.

2. Turn off the air switch of the generator set


3. Turn off the engine switch, and turn the engine switch to "OFF" position

CAUTION
In the case that the speeds handle is on "Stop" position, while the engine is
still running. You should turn the fuel switch to the "OFF" position, or loose the
high pressure oil pipe bolt to stop the engine.
Don't stop the engine with load; you should cut off the load first.

Start switch

CAUTION
Running the starter motor for long time, it may consume the power, even destroy the battery.
Put the start switch at the "ON" position while the engine is running.
2. Battery
You must check the electrolyte each month, if the electrolyte level is below the
lower limit line, please add the water to the upper limit line.

CAUTION
If the electrolyte is too little, the engine will not start. While if the electrolyte is
too much, the electrolyte will corrupt the parts. You should keep the electrolyte
level between the lower limit and upper limit.

7.2 Emergency shut down


1. While the set is running, the operator should keep close watch on the running
state of the set. If there is anything abnormal, you should stop the set following
the right procedure.
2. If there is any emergency, it will result in big destroy or personal accident, such
as the set overspeed, short circuit, electric shock and so on. The operator should
stop the generator decidedly. Press the"emergency stop button", and the
generator will stop immediately.
3. Revolving the "emergency stop button" according to the arrow direction to
replace it.

CAUTION
Don't use the "emergency stop button" in usual cases, which will do certain
harm to your generator.

6.3 Electrical appliance particularly motor-driven equipment will produce very


high current while starting, the below table provides the reference for connecting
these apparatus to the generator set.

WATTAGE
TYPE
STARTIN GRATED

TYPICAL
APPLIANCE

Incandescent
lamp

Incandescent lamp
Heating

X1

X1

X2

X1.5

TV

5.1Operate the generaor set


1. Warm up the engine without load three
minutes.

EXAMPLE
APPLIANCE

STARTIN GRATED

Incandescent
lamp

100W

5. OPERATE THE GENERATOR SET

100VA
(W)

100VA
(W)

80VA
(W)

60VA
(W)

2. Concerning the generator set with Low Oil


Alarm System, check that the Low oil alarm
Lamp is not lit.

appliance

Fluorescent
lamp

40W
Fluorescent
lamp

Fluorescent
lamp

Motor
driven

X3~5

X2

Refrigerator
Refrigerator
150W

equipment

For the generator set with Low Oil Alarm System, the Oil Alarm Lamp will
activated by low oil pressure or engine oil shortage, simultaneously, the
engine will stop. The engine will stop immediately if restarted without
refilling the engine oil. Check the oil level and refill.
Do not loosen or readjust either the engine speed limiting bolt or fuel
injection limiting bolt, the performance will be affected.
450-750VA
(W)

300VA

5.2 Checks during the running


1. Whether there is abnormal sound or vibration;
2. Whether the engine misfires or runs rough;
3. Check the color of the exhaust. (Is it black or too white?)
If you notice any of the above-mentioned phenomenon happened, stop the engine and find out the fault cause or contact with KIPOR agent.

400VA

400VA

If the engine has been running, the muffler will be very hot. Be careful not to
touch the muffler.
Never refill the fuel tank while the engine is running.

Electric fan

Motor

switch power
Rectify power

X2

X2

drill

Electric
Computer

UPS power

Computer UPS
power 200W

CAUTION

CAUTION

6. LOAD
CAUTION
Do not start 2 or more machines simultaneously. Start them one by one.
Do not use floodlights together with other machines.
First start the motor load, and then start resistance load.
6.1 AC application
1. Be sure to run the generator set at rated speed, otherwise AVR (Automatic
Voltage Regulator) will produce the forced excitation. If the running is for a
long time under such condition, AVR will be burned out.
2. After switching on the air switch, observe the voltmeter on the panel of the
control cabinet, the voltmeter should point to 230V 5% 50Hz for singlephase generator set; 400V 5% (50Hz) for three-phase generator set, then
the loading can be carried out.
3. When the double voltage generator set changes over the voltage, the air
switch should be set at "OFF" position. Otherwise the generator set and
electric devices will be burned out and damaged.
4. Connect the equipment to the generator set in order. For the matter of the
motor land, firstly the heavy-duty motor should be connected, then the lightduty motors. If the operation is false, the generator set will lag or stop
suddenly. It is necessary to unload the generator set immediately and turn off
the main switch and do checks.
5. Three-phase generator set
Balance three phases during the operation. Stop the engine for check if the
tolerance exceed 20%. Be sure to keep the tolerance among three phases
less than 20%
The load for each phase must below the rated load as well as the current must
less than rated current.
A,B,C,D(or U,V,W,N) phase arrangement should be from left to right, or
clockwise.
Concerning starting the three phase asynchronous motors, first start the
heavy-duty motors, then start the light-duty motors.

NOTE
If overloading of the circuit trips the AC circuit protector, reduce the electrical
load on the circuit, and wait a few minutes before resuming operation.

6.2 DC application
1. DC terminals are only for charging 12V battery.
2. Set the air switch at "OFF" position while charging. On the 12V output
terminals, a charge switch can be connected so the switch can be used for onand-off purpose.
3. Concerning the automatic type battery with the leads, be sure to disconnect the
negative leads of the battery while charging.

CAUTION
Connect the positive and negative poles of the battery with the positive and
negative poles of DC terminals separately. Do not confuse them, otherwise
the battery and generator set will burn out.
Do not connect the positive pole of the battery with its negative pole,
otherwise the battery damage will result.
Do not connect the positive pole of the DC terminal with its negative pole,
otherwise the generator set damage will result.
When a large capacity battery is charged, excessive current flows, the fuse
for the direct current will burn out.
Do not run the generator set while it is still connected with the battery.
Do not use DC12V and AC at the same time.

CAUTION
Battery exhausts explosive gas. Keep sparks, flames, and cigarettes
away form the battery. To prevent from creating a spark near the battery,
always connect the charging cables to the battery first and only then to
the generator set. When disconnecting, you should disconnect the cables
at the generator set first.
Charge the battery at a well-ventilated place.
Before charging, remove the cap from each cell of the battery.
Stop charging if the electrolyte temperature exceed 45