Kipor K DE2200X/E User manual

DIESEL GENERATOR
SINGLE-PHASE:
K DE2200X/E
K DE3500X/E/T
K DE5000X/E/T
K DE6500X/E/T/TA
K DE6700T/TA
K DA6700TA/TAO
THREE-PHASE:
K DE6500X3/E3/T3
K DE6700T3/TA3
K DA6700TA3/TAO3
MAINTENANCE MANUAL

PREFACE
WARNING
Please read this instruction and ensure understand all regulations concerning
handling, check and maintenance thoroughly prior to application.
Failure to follow this instruction may cause serious accidents.
Incorrect operation is likely to lead accidents.
Operate and maintain the machine on the basis of thorough understanding of this
instruction.
Place this instruction in the fitting box or near machine after reading because it
is regularly needed.
If this introduction is lost or damaged, please order one from local KIPOR
dealer.
Please provide this introduction to another user whom machine will be
transferred to.
Machine may be improved or modified. Therefore actual conditions may be
different from this introduction.
If you have any doubt, please consult local KIPOR dealer.
Machine is the special diesel generator for ground application.
Safety information contained in this introduction are extremely important.
Please read and understand it.

Content
1.Technical Specifications
1.1Main Technical Parameters
1.2Power vs Voltage Diagram of Generating Set Output Characteristic
1.3Overall Dimension Drawing
1.4Electric Principle and Wiring Diagram for Various Models of Generating Set
2.Important Information
2.1Versions Description
2.2Safety
2.3Importance of Proper Maintenance
2.4Important Safety Precautions
2.5Maintenance Regulations
2.6Electric Precautions
2.7Parts Name
2.8Location of Generating Set Series Number
2.9Maintenance Norm for Generating Set
2.10 Torque List (Torque Value)
2.11 Factory Settings of Generating Set
2.12 Troubleshooting Open-shelf Diesel Engine and Quiet Generating Set
2.12.1General Symptom and Possible Cause
2.12.2Flow Chart of Troubleshooting
3.Maintenance Checks
3.1Service List
3.2Checks
3.2.1Check Fuel Oil
3.2.2Check Engine Oil
3.2.3Check Air Cleaner
3.2.4Check Starting Performance of Generating Set
3.2.4.1Recoil Starting
3.2.4.2Electric Starting
3.2.5Check Battery
3.2.6Checks during the Running

3.2.6.1 Check A.C.Output Characteristic
3.2.6.2 Check D.C
3.2.7 Check Overload Operation
3.2.8 Check Stopping of Generating Set
4.Maintenance
4.1Oil-line and intake/exhaust parts
4.1.1Engine Oil
4.1.2Replace Engine Oil
4.1.3Oil Tank / Fuel Oil Filter
4.1.4Oil Pipe / Oil Pump
4.1.5Air Cleaner
4.1.6Muffler
4.2Control Panel
4.2.1A.C. Receptacle
4.2.2D.C. Receptacle or Terminal Post
4.2.3Starting Switch
4.2.4Voltmeter
4.2.5Air Breaker
4.2.6Engine Oil Alerting Apparatus
4.3Generator
4.3.1Generator
4.3.2Installation of Rotor
4.3.3Stator
4.4Cabinet
4.4.1Right Plate
4.4.2Left Plate
4.4.3Cabinet
4.4.4Cabinet Transformer
4.4.5Chassis
5.Service of Intelligent Control Panel for KDE6700TA/TA3
5.1Setting
5.2Check
5.3Maintenance
5.4Parameter Setting List
5.5Diagram of Switch Position for Address Setting

1. SPECIFICATIONS
1-1 Main technical Specifications
Model KDE3500X
KDE3500E
KDE6500X
KDE6500E
KDE3500T
KDE3700T
KDE2200X
KDE2200E
Generating Set
Rated frequency (Hz) Rated output power (kVA) Max. power (kW) Rated current ( A) Rated rotation speed (r/min ) Phase Power factor (cos ) Excitation type DC output Generator structure Generator Insulation grade Pole number
50 50 50 5060 60 60
3.2 3.8 55.5
3.2
3.8
230
3000
240/120
3600 3000 3600 3600 36003000 3000
230 230
230
240/120
240/120
240/120
Single phase
Self-excitation
12V/8.3A
6050 60
1.7
2
230
3000
2.2
240/120
3600
Single phase
3.2 3.8
Rated voltage (V)
7.4 12.2
13.8/27.5
19.6
20.8/41.7
12.2
13.8/27.5
8.3/16.7
12.2
13.8/27.5
2.8 4.5 2.8 2.83.3 3.3 3.352
Single phase Single phase Single phase
1 1 1 1 1
One bearing, Self ventilation
Rotation magnetic field, rotor chute
B B B B
2 2 2 2 2
KM170F KM178F KM186F KM178F KM178F
One cylinder, 4 choke, air cooled, inlined, diesel engine
Engine model Engine type Bore choke (mm) 70 55 78 62 86 72 78 62 78 62

Model
KDE3500X
KDE3500E
KDE6500X
KDE6500E
KDE3500T
KDE3700T
KDE2200X
KDE2200E
Structure type
Engine
Displacement(L)
Compression rate
Rated power kW/(r/min)
Fuel model
Lubricating oil model
Voltage deviation at steady state
Frenquency rate
Voltage wave type distortion rate(zero load)
Insulation resistence(at cold station)
Fuel consumption rate(g/kw.h) Capability of fuel tank(L)
Continuous running time(Hr)
Overall dimension(mm) (L W H)
Net weight (kg)
Starting type
Noise level(dBA/7m)(at rated load)
0.211
20:01
2.5/3000 2.8/3600
0.296 20:01
0.418
19:1
0.296
20:01
0.296
20:01
3.7/3000 4.0/3600 5.7/3000 6.3/3600 3.7/3000 4.0/3600 3.7/3000 4.0/3600
370
15
22
640 480 530
X:53 E:60
77
Open frame
o# (summer), -10# (winter),-35# (chill cold) diesel
SAE10W30(above CC grade)
2.5%
5%
Single phase 5% Three-phase 8%
2M
X:Recoil starter;
E:Recoil starter/Electric starter
370
15
14
640 480 530
70
77
Open frame
360
15
8
720 492 650
X:95 E:100
79
Open frame
370
16
14.5
830 532 740
140
70
Silent
370
16
14.5
845 547 742
150
79
Silent
Recoil starter
/Electric starter
X:Recoil starter;
E:Recoil starter/Electric starter
Electric starter Electric starter
Generating set
Model
KDE6700T/TA/TAO
KDE6500X3/E3/T3
KDE6700T3/TA3/TAO3
KDE6500T
Generating Set
Rated frequency (Hz) Rated output power (kVA) Max. power (kW) Rated current ( A)
Rated rotation speed (r/min )
Phase Power factor (cos ) Excitation type DC output Generator structure Generator Insulation grade Pole number
Single phase
Self-excitation
12V/8.3A
Rated voltage (V)
Single phase
1 1
One bearing, Self ventilation
Rotation magnetic field, rotor chute
B B B
2222
KM186F KM186F KM186F KM186F
One cylinder, 4 choke, air cooled, inlined, diesel engine
Engine model Engine type Bore choke (mm) 86 72 86 72 86 72 86 72
50 50 5060 60
6kVA 7kVA
230
3000
240/120
3600 3000 3600 36003000
400/230
400/230
416/240
416/240
6050 60
4.5
5
230
3000
5.5
240/120
3600
Three phase
19.6 19.6 7.9
20.8/41.7
7.9
5.5kVA 6.3kVA
5
Three phase
0.8(lag) 0.8(lag)
20.8/41.7
4.5
5 5.5
5
6kVA 7kVA
5.5kVA 6.3kVA
8.78.7
No 12V No 12V
B

Note: Explaination for generating set model: KDE is the generating set, 2200 is the set
model. Function code: X is recoil starter E is electric starter set, T is electric starter
silent set, A is digital control panel set, O is automatic starter and automatic change
function with ATS.A, O code only used for above 6700 set model.
Structure type
Engine
Displacement(L)
Compression rate
Rated power kW/(r/min)
Fuel model
Lubricating oil model
Voltage deviation at steady state
Frenquency rate
Voltage wave type distortion rate(zero load)
Insulation resistence(at cold station)
Fuel consumption rate(g/kw.h) Capability of fuel tank(L)
Continuous running time(Hr)
Overall dimension(mm) (L W H)
Net weight (kg)
Starting type
Noise level(dBA/7m)(at rated load)
0.211
20:01
5.7/3000 6.3/3600
0.296
20:01
0.418
19:1
0.296 20:01
5.7/3000 6.3/3600 5.7/3000 6.3/3600 5.7/3000 6.3/3600
360
15
8
910 530 740
165
70
Silent
o# (summer), -10# (winter),-35# (chill cold) diesel
SAE10W30(above CC grade)
2.5%
5%
Single phase 5% Three-phase 8%
2M
370
15 14
915 547 742
177
70
Silent
360
15
8
910 530 740
165
70
Silent
370
16
14.5
915 547 742
177
70
Silent
Electric starter
Generating set
Model
KDE6700T/TA/TAO
KDE6500X3/E3/T3
KDE6700T3/TA3/TAO3
KDE6500T
Electric starterElectric starterElectric starter
Main technical specification of single-phase and three-phase generator sets
Model
Rated frenquency (Hz)
Rated output(kW)
Rated output (V)
Rated current(A)
Phase
Poweer factor (cos )
Rated welding current(A)
Welding work voltage(V)
Welding work
condition (DC)
Welding and generating set
Generating work
condition (AC)
Welding voltage at zero load(V)
Welding continous load rate(%)
Diameter of welding rod (mm)
Adjusting range of welding current (A)
50
2.8
230
12.2
60
3
240
12.5
50
2.8
230
12.2
60
3
240
12.5
Single
1
70-75
160
25-35
60%
30-180
1.6-4.0
Single
1
60-65
160
26
60%
50-180
1.6-4.0
KDE6500XW/EW KDE6700TW
Rated rotation speed r/min
Exciation type
Rectify type
Connecting type
Insulation grade
Voltage deviation at steady state
Frenquency rate
Motor
Pole number
Engine model
Engine type
Displacement(ml)
Bore x stroke(mm)
Compression rate
Rated power Kw/(r/min)
Fuel model
Lubricating oil model
Fuel consumption(g/kw.h)
Oil tank capacity (L)
Continuous running time(h)
Overall dimension(L W H)[mm(in)]
Net weight[kg(1bs)]
Starting type
Noise level [db(A)@7m](at rated load)
Structure
XX
Engine
Set
Voltage wave type distortion rate(zero load)
3000 36000 3000 36000
Self exciation and automatic voltage adjusting(AVR)
IGBT+three-phase rectify bridge(PWM ) IGBT+three-phase rectify bridge(PWM)
Single bearing
2.5%
5%
5%
Rotor chute band damping winding
2
KM186FAG
418
86X72
19
5.7/3000 6.3/3600
2
KM186FAG
418
86X72
19
5.7/3000 6.3/3600
Inlined .single .4-stroke.air cooled Inlined .single .4-stroke.air cooled
SAE10W30 (above CC grade)
360
15
6.5
840x535x650
X 115 E 120
360
16
T:7
915x547x742
188
75
EW/XW Open-frame TW Silent
0#(Summer) -10#(Winter) -35#(Chill cold)Light diesel
XW: Recoil starter EW/TW: Electric starter
70
B B

1-2 The set power and voltage characteristic curves
The following curves indicate generator performance at average conditions. The
performance may vary according to ambient temperature.
Before generator set leave the factory, voltage is set beyond rated voltage. When
generator set start running, output voltage should be equal to rated output, as
load time increase, rated voltage decrease.
(1) AC external characteristic curves of KDE2200X/E generator sets
(2)AC external characteristic curves of KDE3500X/E generator sets
AC
ouput
voltage
V
130
120
110
100
0 2 4 6 8 10 12 14 16 18 20
KDE2200X/E 120V
250
240
230
220
0 2 4 6 8 10
KDE2200X/E 240V
0 2 4 6 8 10
KDE2200X/E
18
16
14
12
10
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
KDE3500X/E 120V
130
120
110
100
KDE3500X/E 240V
0 2 4 6 8 10 12 14 16 18
250
240
230
220
KDE3500X/E
18
16
14
12
10
0 2 4 6 8 10
130
120
110
100
KDE6500X/E 120V
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42
250
240
230
220
0 2 4 6 8 10 12 14 16 18 20 22
KDE6500X/E 240V KDE6500X/E
0 2 4 6 8 10
18
16
14
12
10
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42
KDE6500X/E 120V
130
120
110
100
250
240
230
220
18
16
14
12
10
(3)AC external characteristic curves of KDE6500X/E generator sets
(4)AC external characteristic curves of KDE6500T generator sets
0 2 4 6 8 10 12 14 16 18 20 22
KDE6500X/E 240V KDE6500X/E
0 2 4 6 8 10

(5)AC external characteristic curves of KDE6700T/TA generator sets
(6)AC external characteristic curves of KDE6700T3/TA3 generator sets
(7)AC external characteristic curves of KDE6500EW/XW generator sets
130
120
110
100
KDE6700T/TA 120V
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42
250
240
230
220
0 2 4 6 8 10 12 14 16 18 20 22
KDE6700T/TA 240V KDE6700T/TA
0 2 4 6 8 10
18
16
14
12
10
KDE6500EW/XW
75
70
65
60
55
50
45
40
35
30
25
180 160 120 100 80
60
40
432
416
400
KDE6700T3/TA3 416V/240V KDE6700T3/TA3
250
240
220
0 2 4 6 8
250
240
230
220
0 2 4 6 8
0 2 4 6 8 10 12
0
KDE6500EW/XW
1-3 Overall dimension drawing Unit mm
KDE2200X/E generator sets
KDE3500X/E generator sets

KDE6500X/E/X3/E3 generator sets
KDE6500T/T3 generator sets
KDE6700T/TA/T3/TA3 generator sets
KDE6500XW/EW generator sets
930