KIPOR POWER PRODUCTS CO.

, LTD GENERATOR SHOP MANUAL

KDE5000E KDE5000TA

The Coast Distribution System, Inc. January, 2007

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 owners 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.

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

1. SPECIFICATIONS AND DATA

1.1 Specifications

Model Item Rated frequency (Hz) Rated power (kVA) Rated voltage (ACV) Rated current (ACV) Rated speed (rpm) Phase Power factor Excitation mode DC output AC Receptacles Structure mode Coupling method Gross weight lbs. (kg) Overall dimensions LxWxH in (mm) Generating set Item Model Type Max output (kW/rpm) Bore x stroke in (mm) Displacement in (L) Engine Cooling system Lubricating system Lube oil capacity qt. (L) Starting system Fuel Fuel tank volume gal (L) Run time at rated load- hrs Low oil alarm system

KDE5000E 60 4.5 120/240 37.5/18.8 3600 Single phase 1.0

KDE5000TA 60 4.5 120/240 37.5/18.8 3600

Self excitation constant voltage (AVR) 12V/8.3A 2 120 15A, 1 30A Twistlock, 1 30A 120/240, Open frame Enclosed

Transmission rigid connection 209 (95) 28.3x19.4x25.6 (720x480x845) 376 (171) 36.6x20.3x29.7 (930x515x755)

Model

KDE5000E KM186FAG 4-stroke, single-cylinder, 6.6

KDE5000TA

air-cooled,

direct

injection diesel engine

3.4x2.8 (86x72) 0.418 Forced air-cooled system Pressure splashing 1.5 (1.65) Recoil/electric Diesel 3.9 (15) 8 included 4.2 (16) 8.5 Electric

1-2 KDE5000E wiring diagram

1-3 KDE5000TA wiring diagram

1.4 Component Identification- KDE5000E

1.5 Component Identification KDE5000TA

1.6 Control panel- KDE5000E

OIL ALERT WARNING LAMP START CIRCUIT BREAKERS VOLTMETER SWITCH

20AMP GROUNDING STUD DUPLEX

120VAC

30 AMP 120VAC RECEPTACLE

30 AMP 120/240VAC RECEPTACLE

1.7 Control Panel KDE5000TA

START CIRCUIT BREAKERS SWITCH

DISPLAY PANEL

20A 120VAC DUPLEX

RECEPTACLE

PANEL FUSE

GROUNDING STUD RECEPTACLE

30A 120VAC RECEPTACLE

30A 120/240VAC

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 operators 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 Kipors 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 manufacturers 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 Main Winding Secondary Winding Sampling Winding Charge Winding* Rotor Winding Resistance standard () 0.75-0.85 2.5 0.5 2.5 40-45 Standard value of voltage at No load (V) 240 135 16 13/13 70

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

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2.6 Fasteners and Torque Values (1) KDE5000E

Item Front end cover Rotor through bolt Tighten bolt of fore/back end cover Frame power Hexagonal flange face bolt Hexagonal flange face bolt Hexagonal bolt Earth wire Electromagnet Hexagonal flange face bolt Cross slotted pan head screw Cross slotted pan head screw Anti-hunting bracket Oil tank Hexagonal flange face bolt Hexagonal flange face bolt Hexagonal bolt Decorating plate Hexagonal flange face bolt Hexagonal bolt Carbon brush Rectification block Earth wire Back cover AVR Oil tank assembly Hexagonal flange face bolt Hexagonal flange face bolt Hexagonal flange face bolt Hexagonal flange face bolt Hexagonal bolt Cross slotted pan head screw Cross slotted pan head screw Nut Panel Hydraulic pressure regulator Battery bracket Hexagonal flange face bolt Hexagonal flange face bolt Hexagonal bolt Hexagonal flange face bolt Nnt Battery Butterfly nut M6X18 M8X16 M8 M6X12 M6 M6 9 20 30 9 9 9 7 15 22 7 7 7 Cross slotted pan head screw M5X12 M5X8 M6 M6X16 9 9 7 7 M6X140 M10X45 M10 M6X12 M3X5 M4X8 M8X16 M6X25 M6 M6X25 M6 M5X20 M5X20 M5X12 M5X12 M5 20 9 9 9 9 15 7 7 7 7 10 40 40 9 7 29 29 7 Description Hexagonal flange face bolt Hexagonal flange face bolt Inner diameter of screw X length M8X25 M10X210 Torque Value N.M 18 50 Lbf 13 36

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(2) KDE5000TA
Item Description Inner diameter of screw X length British standard3/8 Front end cover Rotor through bolt Tighten bolt of front/back end cover Frame power Hexagonal flange face bolt Hexagonal bolt Hexagonal bolt Earth wire Muffler Fixed Hexagonal flange face bolt Hexagonal bolt Hexagonal flange face bolt Hexagonal flange face bolt Panel Cross slotted pan head screw Nut AVR Carbon brush Rectification Earth wire Back cover of motor Oil tank Fixed air cleaner Charging regulator Bracket Battery bracket Hexagonal flange face bolt Hexagonal flange face bolt Hexagonal flange face bolt Hexagonal flange face bolt Hexagonal flange face bolt Hexagonal flange face bolt Nut Hexagonal flange face bolt Hexagonal flange face bolt Hexagonal flange face bolt Hexagonal bolt Hexagonal flange face bolt Hexagonal bolt Battery Butterfly nut M6X150 M8 M10 M6X8 M8 M8X25 M6X12 M6X16 M6 M5X16 M5X20 M5X20 M5X12 M5X12 M6X20 M6 M8X25 M6X12 M8X16 M8 M6X12 M6 M6 9 9 20 9 20 20 9 9 9 7 7 15 7 15 15 7 7 7 10 18 50 9 30 20 9 9 9 7 13 36 7 22 15 7 7 7 Hexagonal flange face bolt 16 tooth bolt M10X225 30 50 22 36 Torque Value N.m Lbf

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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: Deteriorated diesel oil in fuel oil Fuel oil is not sufficient Fuel cock is not at START position. Fuel delivery line to fuel tank is bent or pipe is clogged Fuel filter is clogged The injection pump does not deliver fuel Fuel injector does not deliver fuel The governor lever of engine throttle is not at START position Engine oil filter is clogged causing low oil protection Solenoid fuel valve is clogged or does not work because power is off The governor lever of engine throttle is defective The ignition switch fails to engage starter Starting motor is defective Oil alert switch wont allow ignition The battery has is discharged Valves are improperly adjusted Engine is seized Check the 12V power supply and/or replace solenoid valve Check and replace as necessary Check battery condition then check switch Replace Check and replace as necessary Check battery and battery charge regulator Check or adjust valve clearance. Check failure. and observe the engine rotation, disassemble the engine to determine reason for Clean or replace Clean or replace Remove the high pressure fuel line, check for fuel flow, repair or replace pump Remove the fuel injector, check nozzle- clean or replace Switch on Remedy: Drain the fuel oil, check and clean Refill the fuel oil Turn it to START position Check

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(2) Engine speed is unstable, too high or too low (see engine repair manual)
Fault: The fuel supply is insufficient Injection pump or injector is defective Generator has an overload or short circuit fault Engine governor spring is faulty Valves out of adjustment Remedy: Adjust or disassemble to clean Check or replace Repair the fault Repair the fault Adjust

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

Fault: Gauge panel of generating set 1. Circuit breaker fails to function 2. The wiring of gauge panel is loose 3. The connection of Check or replace receptacle receptacle is loose or contact broken. Alternator fault 1. The stator leads are not properly connected 2.The four point output terminal is cracked 3. Short, open, or grounded stator windings 4 Loss of magnetism in main rotor 5. Short, open, or grounded rotor windings 6. Carbon brush assembly defective 7. Insulation resistance of generator is too low. Check resistance values and replace rotor as necessary Check resistance value at slip rings. Check brushes for wear, weak spring tension Check insulation resistance of stator and rotor. Replace stator and rotor as necessary. Check resistance values of all windings. Replace stator is shorted, open or grounded Check AVR Check or replace terminal Check the wiring harness Remedy: Remove it and check for open circuit. The resistance reading in multimeter should be 0 Check the wiring harness.

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(3) AVR fault

1. Voltage can not be regulated 2. Generator set automatically stopped after loading, current setting incorrect 3. Electric component failed 4. Sampling signal but no exciting output 5. The voltage can not be established because of insufficient residual voltage in the stator 6. Power loss is increased because of higher voltage output of the secondary winding 7. The voltage deviation of zero load and full load is too large. 8. Overload shutdown caused by high power factor loading Replace AVR Check exciting output voltage of AVR. Adjust and or replace. Check that the voltage of main winding is 6 V or more with AVR disconnected. Check that the voltage of secondary winding should not greater than 140 VAC - Check AVR and stator. - This may be caused by operating the generator in too high an ambient temperature. Check inductive loads for low power factor and adjust size of load to rated power* Adjust or replace AVR Check output voltage, adjust or replace AVR

* 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: 1. No display on screen. 2. Displays wrong code. 3. Generator cannot start. Remedy: - 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

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(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 OFF ON START --------------------------------------------2 3 4 --------5 ---------6 ---------7 ----------

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

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0.75 to 0.85 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 . (c) Sampling winding: On the same 4 pin connector, check the resistance between the two yellow wires. The value is 0.5 . (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 . (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) 2) Insert the semicircle clip ring into key groove. 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

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4-3 Battery Charge Regulator

4.4 Current Transformer

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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

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

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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 my be blue instead of green

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4.9 Charge Winding Check

Note: use the values for the KDA6700TA for both the KDE5000E and KDE5000TA 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 ON OFF X X X 4 X X 5

(5) The three position DIP switch board is factory set but make sure the settings are as follows: 1 ON OFF X 2 X 3 X

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