Kipor IG3000E User manual

PREFACE
Thank you for purchasing a Kipor Generator.
This manual covers the operation and preventive maintenance of the IG3000E generator
with EPAand California Air Resources Board (CARB) certification if so designated.
All information in this publication is based on the latest product information available at
the time of printing.
We reserve the right to make changes at any time without notice and without incurring
any obligation.
No part of this publication may be reproduced without written permission.
This manual should be considered a permanent part of the generator and should remain
with it if it is resold.
Pay special attention to statements preceded by the following words:
Failure to properly follow these precautions can result in property
damage, serious injury or DEATH!
Read all labels and the owner's manual before operating this generator.
Generators produce carbon monoxide, a poisonous, colorless, odorless gas that can
cause death or serious injury.
Indoor use of a generator can kill quickly. Generators should be used outdoors only.
Generators should be used outdoors only and away from garages and open windows
and protected from rain and snow.
Always stop the engine before refueling. Wait 5 minutes before restarting.
Keep any source of ignition away from the fuel tank at all times.
The portable generator is not meant to be used as a permanent back-up power system
for the home. A permanently installed stationary generator is designed to be safely used
for this specific purpose.

Indicates a strong possibility of severe personal injury or death if
instructions are not followed.
Indicates a possibility of personal injury or equipment damage if
instructions are not followed.
NOTE Gives helpful information.
If a problem should arise or if you have any questions about the generator, please
consult an authorized dealer or service center.
Our generators are designed to give safe and dependable service
if operated according to the instructions. Read and understand
the Owner's Manual before operating the generator. Failure to do
so could result in personal injury or equipment damage.

CONTENTS
1. SAFETY INSTRUCTIONS··················································································1
2. COMPONENT IDENTIFICATION·········································································3
3. PRE-OPERATION CHECK·················································································5
4. STARTING THE ENGINE ··················································································9
5. GENERATOR USE·························································································11
6. STOPPING THE ENGINE················································································16
7. MAINTENANCE·····························································································17
8. TRANSPORTATION, STORAGE AND EXERCISE················································20
9. TROUBLESHOOTING ····················································································21
10. SPECIFICATIONS························································································23
11. WIRING DIAGRAM·······················································································24
12. WARRANTY································································································25
13. EMISSION CONTROL SYSTEM······································································30

1
1. SAFETY INSTRUCTIONS
■Our generators are designed to give safe and
dependable service if operated according to these
instructions.
Read and understand the owner's manual before
operating the generator. Failure to do so could result in
personal injury or equipment damage.
■Exhaust gas contains poisonous carbon monoxide.
Never run the generator in an enclosed area.
Be sure to provide adequate ventilation.
The muffler becomes very hot during operation and
remains hot for several minutes after stopping the
engine.
Be careful not to touch the muffler while it is hot.
Let the engine cool before storing the generator
indoors.
The engine exhaust system will be heated during
operation and remain hot immediately after stopping
the engine.
To prevent scalding, pay attention to the warning marks
attached to the generator.
The generator must be operated outside with adequate
ventilation. It cannot be operated in an enclosed
compartment of any vehicle or garage area.

2
To ensure safe operation:
■Gasoline is extremely flammable and explosive under
certain conditions. Refuel in a well ventilated area with the
engine stopped.
■Keep away from smoking materials, sparks and other
sources of combustion when refueling the generator.
Always refuel in a well-ventilated location.
■Wipe up spilled gasoline at once.
■Restrict application of generator in high-hazard risk to
causing fire area.
■Connections for standby power to a building's electrical
system must be made by a qualified electrician and must
comply with all applicable laws and electrical codes.
Improper connections can allow electrical current from the
generator to back feed into the utility lines. Such back feed
may electrocute utility company workers or others who
contact the lines during a power outage, and when utility
power is restored, the generator may explode, burn, or
cause fires in the building's electrical system. This
generator is not designed to be connected to an automatic
transfer switch. Serious damage to the engine and inverter
module may result.
■Always make a pre-operation inspection before you start
the engine.
■Place the generator at least three feet or one meter away
from buildings or other equipment during operation.
■Operate the generator on a level surface to prevent fuel
spillage or oil starvation.
■Know how to stop the generator quickly and understand
operation of all the controls. Never permit anyone to
operate the generator without proper instructions. Keep
children and pets away from the generator when it is in
operation.
■Never operate the generator with the door open or any
panels removed. Do not operate in any enclosure such as
an RV compartment.
■Keep away from rotating parts while the generator is
running.
■The generator is a potential source of electrical shocks
when misused; do not operate with wet hands.
■Do not operate the generator in rain or snow or let it get
wet.

3
2. COMPONENT IDENTIFICATION
2.1 Outline drawing
Fuel Tank
Fuel filler cap
Frame
Control panel
Recoil starter handle
Spark plug
Fuel gauge
Fuel valve
Air filter
Alternator
Oil fill
Oil drain plug
Muffler
Choke knob

4
2.2 Control panel
2.3 Serial Number Location:
The serial number is stamped on the engine block to the left of the oil drain plug. Refer to
this number when ordering parts or making technical inquiries.
E n gin e s e ria l n um b er
Please record this information below and keep this manual in a safe place along with the
bill of sale.
Serial Number __________________________________
Date of Purchase ________________________________
Engine serial number
AC output indication (green)
Overload indication (red)
Low oil level indication (red)
DC Receptacle
Smart Throttle Switch
Ignition Switch
Status Indicator
120V 30A Receptacle
Circuit Protector
120V 20A Receptacle
Overload Reset Switch
Ground Terminal

5
3. PRE-OPERATION CHECK
CAUTION
■Check the generator on a level surface with the engine stopped.
3.1 Engine Oil
NOTE
■Using non detergent oil or 2-stroke engine oil could shorten the engine's service life.
■Use a high-detergent, premium quality 4-stroke engine oil, certified to meet or
exceed U.S. automobile manufacturer's requirements for API Service Classification SG,
SF.
■Select the appropriate viscosity for the average ambient temperature in your area.
SAE Viscosity Grades
Ambient Temperature
Check the engine oil level
Remove the oil filler cap, and wipe the dipstick with a clean rag. Check the oil level by
inserting the dipstick in the filler hole without screwing it in.
NOTE
■The Low OilAlarm System will automatically stop the engine before the oil level falls
below the safe limit. However, to avoid the inconvenience of an unexpected shutdown, it
is still advisable to visually inspect the oil level regularly.
Single
viscosity
Multi-
viscosity
Dipstick
Oil drain bolt
Upper limit
Lower limit
Oil fill port

6
3.2 Fuel
If the fuel level is low, refuel the fuel tank to the specified level..
After refueling, tighten the fuel filler cap securely.
Use unleaded 87 octane regular grade gasoline only.
WARNING
■Never use an oil/gasoline mixture or old, dirty gasoline. Avoid getting dirt, dust or
water in the fuel tank.
WARNING
■Gasoline is extremely flammable and is explosive under certain conditions.
■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 gasoline is stored.
■Do not overfill the fuel tank (there should be no fuel above the upper limit mark).
After refueling, make sure the tank cap is closed properly and securely.
■Be careful not to spill fuel when refueling. Spilled fuel or fuel vapor may ignite, If any
fuel is spilled, make sure the area is dry before starting the engine.
■Avoid repeated or prolonged contact with skin or breathing of vapors. KEEP OUT
OF REACH OFCHILDREN.
GASOLINES CONTAINING ALTERNATE FUELS
If you decide to use a gasoline containing ethanol be sure its octane rating is no lower
than 87. Do not use a blend that contains more than 10% ethanol. Use of the new E15
fuel is strictly prohibited. Do not use any gasoline containing methanol.
NOTE
■Fuel system damage or engine performance problems resulting from the use of
fuels that contain an improper blend of ethanol or methanol is not covered under the
warranty.
■Before buying fuel from an unfamiliar station, try to find out if the fuel contains
ethanol. If it does, confirm the type and percentage of ethanol used. If you notice any
undesirable operating symptoms while using a gasoline that contains ethanol, or one
that you think contains ethanol, replace it by a gasoline that does not contain ethanol.

7
3.3 Air Cleaner
Check the air cleaner element to be sure it is clean and in good condition.
Unsnap the two clips, remove the element from the air cleaner cover and check it for
cleanliness. Replace the element if the paper is dirty or torn or the rubber frame is brittle
or distorted.
■Never run the engine without the air cleaner. Rapid engine wear will result from
contaminants such as dust and dirt being drawn through the carburetor into the engine.
3.4 High altitude operation
High altitude performance can be improved by installing a smaller diameter main fuel jet
in the carburetor. If you always operate the generator at altitudes higher than 5,000 feet
(1500M) above sea level, have your authorized KIPOR dealer perform these carburetor
modifications.
Even with suitable carburetor jetting, engine horsepower will decrease approximately
3.5% for each 1000 feet (300M) increase in altitude. The affect of altitude on the
horsepower will be greater than this if no carburetor modification is made.
Element
Air cleaner cover
Clips

8
Operation of the generator at an altitude lower than the
carburetor is jetted for may result in reduced performance,
overheating, and serious engine damage caused by an
excessively lean air/fuel mixture.
3.5 Ambient Temperature
Generator output generally declines 1% for every 10° F (5.5° C) above 85° F (29° C).
The normal operating range of the generator is -20° to 113° F (-29° to 45° C).
■Do not operate the generator when the ambient
temperature is below -20° F (-29°)
■Do not operate the generator when the ambient
temperature is above 113° F (45° C)

9
4. STARTING THE ENGINE
■When starting the generator after adding fuel for the first time
or after long term storage or after running out of fuel, turn the
fuel valve lever to the "ON" position and wait10 to 20 seconds
before starting the engine.
Disconnect all loads from the AC receptacles before starting the engine.
4.1 Turn the fuel valve handle to the "ON" position. Pull out the choke knob.
4.2 Turn the engine switch to the "START" position to start the engine.
Pull the choke knob
towards you.
Fuel Handle
Turn the fuel valve handle to "ON" position.
4.3 Insert the engine key and turn the engine switch to the “ON’ position.
4.4 (a) Electric Start: turn the engine switch to the START until the engine has started. Do
not operate the starter for more than 10 seconds.
4.4 (b) Manual Start: pull the starter grip lightly until resistance is felt then pull the starter
grip briskly toward the arrow as shown below.
ELECTRIC START:

10
RECOIL START:
■Do not allow the starter grip to snap back. Return it
slowly by hand.
■Do not let the starter rope rub against the generator
body or the rope will wear out prematurely.
4.5.After the engine has started and warmed up, push the choke knob back in.
Pull starter handle
straight towards you
OFF
CHOKE KNOB
Pull towards
you TOWARDS
ON
START

11
5. GENERATOR USE
■To prevent electrical shock from faulty appliances, the
generator should be grounded. Connect a length of
heavy cable between the generator's ground terminal
and an external ground source.
■Connections for standby power to a building's electrical system must be made by a
qualified electrician and must comply with all applicable laws and electrical codes.
Improper connections can allow electrical current from the generator to back feed into
the utility lines. Such back feed may electrocute utility company workers or others who
contact the lines during a power outage; when utility power is restored, the generator
may explode, burn, or cause fires in the building's electrical system. Do not connect this
generator to an automatic transfer switch. Serious damage to the engine and inverter
module may result.
■ Limit operation requiring maximum power to 30 minutes.
For continuous operation do not exceed the rated power of 2800 watts or 23.3 amps.
■ Do not exceed the current limit specified for any one receptacle.
■ Do not modify or use the generator for other purpose other than what it was intended.
Also observe the following when using the generator:
Do not attempt to connect generators in parallel.
Do not connect an extension to the exhaust pipe.
Do not operate with any covers removed or in a closed compartment
■ When an extension cable is required, make sure you use the proper size and length.
16 Gauge Cord- any 16 gauge cord between 0 and 100 feet long will adequately handle tool
and appliance loads up to 10 amps
14 Gauge Cord- a 14 gauge cord between 0 and 50 feet long will adequately handle loads
between 10 and 15 amps.
12 Gauge Cords- if your load is between 10 and 15 amps and the length of the cord is 50 to
100 feet, you need a 12 gauge cord to safely power any tool.
■ Keep the generator away from other electric cables or wires such as commercial
power supply lines.
■ You may use the DC receptacle and AC power simultaneously.

12
5.1 AC power application
1. Start the engine and make sure the green output indicator light comes on.
2. Confirm that the appliance to be used is switched off then plug in the appliance.
■Be sure that all appliances are in good working order
before connecting them to the generator. If an
appliance begins to operate abnormally, becomes
sluggish, or stops suddenly, turn off the generator
engine switch immediately. Disconnect the appliance
and examine it for signs of malfunction.
5.2 Output and Overload Indicators
The green output indicator light will remain on during
normal operating conditions. If the generator is overloaded
to the point that the max power rating of 25 amps is
exceeded or if there is a short in the connected appliance
the output indicator will go out and the overload indicator
will go on and current to the connected appliance will be
shut off. Stop the engine if the overload indicator light
comes ON and investigate the overload source. The engine
will continue to run even though it is not producing any AC
power. The engine must be stopped and then the generator
restarted to resume normal operation.
The 5-20R single receptacle is rated at 20 amps. Should
this current be exceeded, the circuit protection device will
activate and cut all current to the receptacle. This will be
indicated by the push button popping out. Reduce the load
to the receptacle and reset the circuit protector by pushing
in the button.
■Before connecting an appliance to the generator, check
that it is in good order and that its electrical rating does
not exceed that of the generator. .
■When an electric motor is started, both the overload
indicator light and the output indicator light may go on
simultaneously. This is normal if the overload indicator
light goes off after about four seconds. If the overload
indicator light stays on, consult a service center.

13
5.3 SMART Throttle
Engine speed is kept at idle automatically when the electrical load is disconnected and
returns to the proper speed by the electrical load when the load is reconnected. The
engine speed varies according to the amount of load applied to the generator. Placing
the smart throttle in the on position is recommended to minimize fuel consumption and
engine noise while in operation.
■When high electrical load appliances are connected
simultaneously, turn the SMART throttle switch to the
OFF position to reduce voltage fluctuation.
■The SMART throttle system does not operate efficiently
if the electrical appliance will be used in a rapid on-off
or low to high rpm mode.
When the smart throttle is in the off position, the engine runs at rated load RPM.
5.4 Overload Reset Switch
Should the generator overload, AC power will be cut off but the engine will stay running.
Correct the overload condition and then press the overload reset switch on the front
panel.AC power will be restored immediately.
5.5 Air Conditioning Operation
For best results, the SMART throttle switch should be in the OFF position. Bring the
generator to a normal operating temperature before applying the air conditioning load.
Always allow a 2 minute wait period when manually cycling an air conditioner off and on.
A longer wait period may be required under unusually hot weather conditions.
Additionally, all other loads should be turned off until the air conditioner has started and is
performing normally. It is also important to follow the air conditioner manufacturer's
instructions for starting and restarting for proper operation. Some air conditioner
manufacturers offer a start capacitor as an extra cost option. The lack of a start capacitor
can cause the air conditioner to draw too high a starting current and overload the
generator. Contact your air conditioner dealer if you consistently have problems starting
your air conditioner with the generator. This generator is not generally recommended for
air conditioners exceeding 13,500 BTUs.

14
5.6 DC application
The DC receptacle may be used for charging 12 volt automotive-type batteries only. It is
not designed to operate DC motors. Output voltage is 15-30V. DC output will vary
according to the position of the Smart throttle switch.
1. Connect the charging cable to the DC receptacle of the generator and then to the
battery terminals.
■ To prevent the possibility of creating sparks near the battery,
connect the charging cable first to the generator then to the
battery. Disconnect the cable first at the battery.
■ Before connecting the charging cable to a battery that is
installed in a vehicle, disconnect the vehicle's battery
ground cable. Reconnect the vehicle's ground cable after
the charging cables are removed. This procedure will
prevent the possibility of a short circuit and sparks if
accidental contact is made between a battery terminal and
the vehicle's frame or body.
■ Do not attempt to start an automobile engine with the
generator still connected to battery. The generator may be
damaged.
■ Connect the positive battery terminal to the positive
charging cord. Do not reverse the charging cables or
serious damage to the generator and/or battery may occur.
■ The battery gives off explosive gases: keep sparks, flames
and cigarettes away. Provide adequate ventilation when
charging.
■ The battery contains sulfuric acid (electrolyte). Contact with
skin or eyes may cause severe burns. Wear protective
clothing and a face shield.
A. If electrolyte gets on your skin, flush with water.
B. If electrolytes gets in your eyes, flush with water for at
least 15 minutes and call a physician.
■ Electrolyte is poisonous.
If swallowed, drink large quantities of water or milk and
follow with milk of magnesia or vegetable oil and call a
physician.
■ Keep out of reach of children.

15
The DC output is to be used to charge batteries only. Serious
damage to the stator windings can occur if connected to a DC
motor or transformer.
2. Start the generator.
■ The DC receptacle may be used while the AC power is in use.
■ The DC receptacle is protected from an overload with a fuse. If the DC circuit is
overloaded, the 5 amp fuse will blow and power to the DC receptacle will cease. The red
light on the DC panel will illuminate. The fuse is located behind the door to the left of the
receptacle. Replace the fuse with one of the same capacity. Using a higher rated fuse
may cause damage to the generator alternator.
5.7 Low oil alarm system
The low oil alarm system is designed to prevent engine damage caused by an
insufficient amount of oil in the crankcase. Before the oil level in the crankcase falls
below a safe limit, the low oil alarm system will automatically shut down the engine (the
engine switch will remain in the ON position).
If the low oil alarm system shuts down the engine the red low oil alarm indictor light will
come on when you operate the starter, and the engine will not run. If this occurs, search
for any oil leaks. Add engine oil to resume normal operation.
Fuse
DC Receptacle
Open

16
6. STOPPING THE ENGINE
To stop the engine in an emergency, turn the engine switch to the OFF position.
IN NORMAL USE:
1. Switch off connected loads and pull the plugs from the receptacles.
2. Turn the engine switch to the OFF position.
3. Turn the fuel valve lever to the OFF position.
Continually stopping the generator with a load attached will lead to damage of the
inverter module. Switch off all connected loads before stopping the generator.