Kipor KGE4000X User manual

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.
No part of this publication may be reproduced without written permission.
SERVICE MANUAL
www.kipor.com.au
For more information contact Customer Service on 1300 555 197
Distributed by
PRIMUS AUSTRALIA PTY LTD
Bundoora VIC 3083
www.primusaustralia.com.au

PREFACE
Thank you for purchasing a Kipor generator.
This manual covers the operation and maintenance of models KGE2500X, KGE4000X, KGE6500X
and KGE6500E Open Frame single phase petrol generators.
All information in this publication is based on the latest product information available at the time
of approval for printing.
We reserve the right to make changes at any time without notice and/or 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, colourless and
odourless gas that can cause death or serious injury.
Indoor use of a generator can kill quickly. This generator should only be
used outdoors in a well ventilated area, protected from rain and snow.
Check for spilled fuel or leaks. Clean and/or repair before use.
Always stop engine before refuelling. Wait 5 minutes before restarting.
Keep any source of ignition away from fuel tank at all times.
This portable generator is not to be used as a permanent back-up
power system for the home or any building electrical circuits.
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.
If a problem should arise, or if you have any questions about the generator, consult an authorised
dealer.
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.
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CONTENTS
1. SAFETY INSTRUCTIONS 3
2. IDENTIFICATION OF COMPONENTS 5
3. PRE-OPERATION CHECK 6
4. STARTING THE GENERATOR 9
5. GENERATOR USE 10
6. STOPPING THE GENERATOR 14
7. MAINTENANCE 15
8. TRANSPORTING AND STORAGE 20
9. TROUBLESHOOTING 22
10. SPECIFICATIONS 23
11. WARRANTY 24
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1. SAFETY INSTRUCTIONS
To ensure safe operation -
•This generator is designed to give safe and dependable service if
operated according to 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.
Use Outdoors only – in a well ventilated area.
•The muffler becomes very hot during operation and remains hot for
several minutes after stopping the engine.
Be careful not to touch the muffler or exhaust system while it is hot.
Let the engine cool before storing or transporting the generator.
•To prevent burns, pay attention to the warning marks attached to
the generator.
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SAFETY INSTRUCTIONS cont.
To ensure safe operation -
•Petrol is extremely flammable and explosive under certain conditions. Stop the engine before
refuelling – Do not overfill.
•Keep away from cigarette smoke, sparks and other flammable materials when refuelling or
operating the generator. Always refuel in a well-ventilated location.
•Wipe up spilled petrol immediately.
•Do not connect the outlet/s of the generator to any household or building electrical circuits.
•Always complete a pre-operation check (page 7) before you start the engine. You may prevent
an accident or equipment damage.
•Read the Owner’s Manual before use and understand the operation of all controls especially
how to stop the generator quickly. Never allow anyone to operate the generator without
proper instruction.
•Place the generator at least 1m (3 ft) away from any buildings or other equipment
during operation.
•Only operate the generator on a clean and dry level surface to prevent fuel spillage or oil
starvation. If the generator is tilted, a fuel spillage may result.
•Keep children and pets away from the generator when it is in operation.
•Keep away from rotating parts while the generator is running.
•The generator is a potential source of electrical shock when misused; do not operate with
wet hands.
•Do not operate the generator in rain or snow or wet conditions and do not let it get wet.
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2. IDENTIFICATION OF COMPONENTS
Read all labels, safety instructions and precautions described in this Owner’s Manual carefully.
These labels warn you of potential hazards that can cause serious injury.
If a label comes off or becomes hard to read, contact your authorised dealer for a replacement.
1/ Fuel tank 10/ Starter handle
2/ Engine starter switch 11/ Air cleaner
3/ AC breaker 12/ Fuel tap
4/ Fusible cut-out 13/ Choke level
5/ DC terminal 14/ Fuel tank cap
6/ AC receptacle 15/ Framework
7/ Grounding terminal 16/ Exhaust muffler
8/ Oil filler dipstick 17/ Spark plug
9/ Oil drain plug
Serial Number Location
The serial number identifies the particular generator and is important when ordering spare parts
for any warranty or service maintenance.
The serial number can be found
stamped on the engine block
below the oil filler dipstick.
5
KGE2500X / KGE4000X / KGE6500X / KGE6500E
Serial Number
Oil Filler Dipstick
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3. PRE-OPERATION CHECK
•Be sure to check the generator is on a level and dry surface with the engine stopped.
STEP 1 . Check the engine oil level.
•Using a non-detergent oil or 2-stroke engine oil could shorten the engine's service life.
It is recommended to use SAE 10W-30 Grade engine oil.
Only 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.
To Check Oil Level
Remove the oil filler dipstick, and wipe the dipstick with a clean rag.
Insert the oil filler dipstick into the filler hole without rotating it.
If the oil level is below or at the lower end of the dipstick, refill with the recommended oil up to the
upper level mark. Tighten the oil filler dipstick.
Oil Capacity: KGE2500X 0.6Lt
KGE4000X 1.1Lt
KGE6500X/E 1.1Lt
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3. PRE-OPERATION CHECK cont.
•Running the engine with insufficient oil can cause serious engine damage.
NOTE: The Low Oil 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 on a daily and regularly basis.
STEP 2. Check the fuel level.
Use ONLY Unleaded Petrol.
Remove fuel tank cap (anti-clockwise). If the fuel level is low, refill the fuel tank until the level
reaches the upper limit mark at the top of the fuel filter.
Do not use an oil/petrol mixture or dirty or contaminated petrol.
Avoid getting dirt, dust or water in the fuel tank.
After refuelling, tighten the fuel tank cap securely.
•Petrol 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 generator is being refuelled.
•Do not overfill the fuel tank - there should be no fuel above the upper limit mark. After refuelling,
make sure the fuel filler cap is tightened securely.
•Be careful not to spill fuel when refuelling. Spilled fuel or fuel vapour may ignite. If any fuel is
spilled, make sure the area is dry before starting the engine.
•Avoid repeated or prolonged contact of petrol with skin or breathing of petrol vapour.
•KEEP OUT OF REACH OF CHILDREN.
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3. PRE-OPERATION CHECK cont.
Fuel tank capacity: KGE2500X 25Lt
KGE4000X 30Lt
KGE6500X/E 30Lt
•Fuel system damage or engine performance problems resulting from the use of fuels other than
Unleaded Petrol, are not covered under the warranty policy.
STEP 3 . Check the air cleaner.
Unclip and remove the air cleaner cover. Remove the foam air cleaner element and inspect.
Check to ensure it is clean and in good condition.
Clean or replace the element if necessary (refer page 18 for air cleaner service maintenance).
•Never run the engine without the air cleaner. Rapid engine wear will result from contaminants
such as dust and dirt being drawn through the carburettor into the engine.
8
Foam element
Air filter cover
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4. STARTING THE GENERATOR
Before starting the engine
Step 1. Disconnect any leads from the
AC receptacles and DC terminals.
Switch OFF the AC Circuit Breaker.
Step 2. Turn the fuel tap to ON position.
Step 3. Pull the choke lever to
CHOKE position.
Step 4. Turn the engine / starter switch to
the ON position.
Step 5. Pull the starter grip until resistance
is felt, then pull firmly.
For KGE6500E Electric Start
model, turn key clockwise to START
position and release.
•Do not allow the starter grip to snap back, Return it slowly by hand.
Step 6. Move the choke lever to the RUN
position after the engine has started.
•If the engine stops and will not restart, check the engine oil level and fuel tank level before
further troubleshooting.
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5. GENERATOR USE
Be sure to ground the generator when the connected equipment is grounded.
•To prevent an 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.
•It is recommended that this generator not be connected for standby power to any household
or building's electrical circuits. Improper connections can allow electrical current from the
generator to back feed into the utility lines. Such back feed may electrocute workers or other
persons 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 the generator to an automatic transfer device. Severe damage to the generator
may result.
•The total wattage of all appliances connected must be considered.
•Do not exceed the current limit specified for any one receptacle.
•Do not connect the generator to any household circuit. This could cause damage to
the generator or to electrical appliances in the house.
•Do not modify or use the generator for purposes other than it is intended for.
•Do not connect an extension to the exhaust pipe.
•When an extension cable is required, be sure to use a rubber sheathed flexible cable
(IEC 245 or equivalent).
•Limit length of extension cables to 60m (195 ft) for cables of 1.5mm2 and 100m (325 feet) for
cables of 2.5mm2 . Long extension cables will reduce usable power due to resistance in the
extension cable.
•Keep the generator away from other electric cables or wires such as commercial power
supply lines.
•The DC terminals can be used while the AC power is in use. If you use both at the same time,
be sure not to exceed the total power for AC and DC.
•Most appliance motors require more than their rated wattage for start-up.
10
Ground Terminal
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5. GENERATOR USE cont.
AC Application
STEP 1. Start the engine
STEP 2. Check that the appliance/s to be used are switched off.
Plug appliance/s into AC receptacle/s.
STEP 3 . Switch ON the AC Circuit Breaker.
Electrical appliances particularly motor-driven equipment will produce very high current while
starting. The table below is a guide when connecting these appliances.
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5. GENERATOR USE cont
•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. 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.
•In order to insure the optimum output and the maximum service life of the generator, the
generator should run at a 50% load for the first 20 hours.
DC Terminals
The DC Terminals may be used for charging 12 volt automotive-type batteries only.
The zero load voltage is 15V-30V.
•To prevent the possibility of creating a spark near the battery, connect charging cables first to
the generator, then to the battery. When disconnecting reverse this procedure.
•Before connecting charging cables to a battery that is installed in a vehicle, disconnect the
vehicles grounded battery cable. Reconnect the vehicle's grounded battery cable after the
charging cables are removed. This procedure will prevent the possibility of a short circuit and
spark if you make accidental contact between a battery terminal and the vehicle's frame
or body.
•Do not attempt to start a vehicle’s engine with the generator still connected to the 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 DC output is for battery charging only. Do not utilise to operate any DC appliances
or motors.
•The battery gives off explosive gases; keep away from sparks, flames and cigarettes. Provide
adequate ventilation when charging.
•The battery contains sulphuric acid (electrolyte). Contact with skin or eyes may cause severe
burns. Always wear protective clothing and safety glasses.
-If electrolyte gets onto skin, flush with water.
-If electrolyte gets into 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 THE REACH OF CHILDREN.
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5. GENERATOR USE cont
Low Oil Alert System
The low oil alert 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 alert
system will automatically shut down the engine, even when the engine switch is in the ON position.
If the low oil alert system shuts down the engine, check the oil level and add the recommended
engine oil.
High Altitude Operation
At higher altitudes, the standard carburettor air-fuel mixture will be excessively rich. Performance
will decrease, and fuel consumption will increase. Power output will decrease 3.5% for each 300m
(1000 feet) above sea level.
High altitude performance can be improved by installing a smaller diameter main fuel jet in the
carburettor. If you always operate the generator at altitudes higher than 1500m (5000 feet) above
sea level, have your authorised dealer install a high altitude main jet.
Even with suitable carburettor jetting, engine horsepower will decrease approximately 3.5% for
each 300m (1000 feet) in increased altitude. The affect of altitude on the reduction of horsepower
will be greater if no carburettor modification is made.
•Operation of the generator at an altitude lower than the carburettor is jetted, may result in
reduced performance, overheating, and serious engine damage caused by an excessively lean
air/fuel mixture.
•Be sure to have any modification reversed at lower altitudes.
Temperature
High temperature unfavourably affects generator operation. Generator performance will decrease
1% for each 5.5°C (10°F) increase in temperature above 29°C (85°F).
The normal operating range of this generator is -29° to 45°C (-20° to 113°F).
•Do not operate the generator when the ambient temperature is below -29°C ( -20°F).
•Do not operate the generator when the ambient temperature exceeds 45°C (113°F).
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6. STOPPING THE GENERATOR
To stop the generator in an emergency, turn the engine switch to the OFF position.
In Normal Use
STEP 1.
Switch OFF all connected appliances.
STEP 2. Switch OFF AC Circuit Breaker.
STEP 3. Switch OFF the engine / starter switch.
STEP 4. Turn Fuel Tap to OFF position.
•Make sure that the engine / starter switch and fuel tap are in the "OFF" position when the
generator is not in use or being transported and/or stored.
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7. MAINTENANCE
The purpose of the inspection and maintenance schedule is to keep the generator in the best
operating condition.
Inspect and service this generator as scheduled in the table below.
•Shut off the engine before performing any maintenance. If the engine must be run, make sure
the area is well ventilated. The exhaust gas contains poisonous carbon monoxide.
•Use only genuine parts or their equivalent. The use of replacement parts which are not of
equivalent quality may damage the generator.
Maintenance Schedule
NOTE:
(1) Service more frequently when used in dusty areas.
(2) These items should be serviced by your authorised dealer, unless you have the proper tools
and are mechanically proficient. Refer to the workshop manual for service procedures.
(3) For commercial use, log hours of operation to determine proper maintenance intervals.
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7.1 CHANGING OIL
Drain the oil while the engine is still warm to assure rapid and complete draining.
•Make sure the engine / starter switch and the fuel tap is OFF before draining oil.
Step 1. Remove the oil filler dipstick.
Step 2. Remove oil drain plug and drain all used dirty oil into a container.
Step 3. Refit oil drain plug and tighten securely.
Step 4. Refill with the recommended SAE10W/30 Grade Oil and check the oil level.
Step 5 . Re-install oil filler dipstick and tighten securely.
Engine Oil Capacity: KGE2500X 0.6Lt
KGE4000X 1.1Lt
KGE6500X/E 1.1Lt
•Please dispose of used engine oil in a manner that is compatible with the environment. We
suggest you take it in a sealed container to your local recycling centre. Do not throw it in the
rubbish or pour it on the ground.
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Drain Plug
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7.2 AIR CLEANER SERVICE
A dirty air cleaner will restrict air flow to the carburettor. To prevent carburettor malfunction, service
the air cleaner regularly. Service more frequently when operating the generator in extremely dusty
areas.
•Do not use petrol or low flash point solvents for cleaning. They are flammable and explosive
under certain conditions.
•Never run the generator without the air cleaner, otherwise rapid engine wear may result.
Step 1. Unclip and remove air cleaner cover.
Step 2. Remove foam air cleaner element and inspect.
Step 3. Wash the element in a non-flammable or high flash point solvent and dry thoroughly.
Step 4. Soak the element in clean engine oil and squeeze out excess oil.
Step 5. Replace the element if torn or damaged and unable to be cleaned properly.
Step 6 . Re-install the element and refit the air cleaner cover.
17
Foam element
Air filter cover
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7.3 SPARK PLUG SERVICE
Recommended Spark Plug: KGE2500X BPR5ES (NGK)
KGE4000X BPR5ES (NGK)
KGE6500X/E BPR5ES (NGK)
To ensure proper engine operation, the spark plug must be properly gaped and free of deposits.
Only use the recommended spark plug in the generator.
Step 1. Remove the spark plug cap.
Step 2. Clean any dirt from around the spark plug base.
Step 3. Use the spark plug spanner to remove the spark plug.
Step 4. Inspect the spark plug. Replace it if the electrodes are worn or if the insulator is cracked
or chipped. Clean the spark plug with a wire brush if it is to be reused.
Step 5. Measure the plug gap with a feeler gauge. The gap should be 0.7~0.8mm
(0.028-0.032in). Adjust as necessary by carefully bending the side electrode.
Step 6. Install the spark plug carefully by hand, to avoid cross-threading.
Step 7. After a new spark plug has been seated by hand, it should be tightened 1/2 turn with the
spark plug spanner to compress the washer. If a used plug is being re-installed, it should
only require 1/8 to 1/4 turn after being seated.
Step 8 . Re-fit the spark plug cap onto the spark plug securely.
•The spark plug must be securely tightened. A loose spark plug can overheat and damage
the generator.
•Do not use a spark plug with the incorrect heat range.
18
0.7~0.8mm
(0.028-0.032in)
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7.4 SPARK ARRESTOR MAINTENANCE
•If the generator has been running, the muffler will be very hot. Allow it to cool before proceeding.
•The spark arrestor must be serviced every 100 hours to maintain its efficiency.
Step 1. Unscrew and remove the clamp retaining the spark arrestor.
Step 2. Remove the spark arrestor from the muffler.
Step 3 . Use a wire brush to remove carbon deposits from the spark arrestor screen. Be careful
to avoid damaging the screen. Inspect the screen for holes, and replace if necessary.
Step 4. Re-install the spark arrestor in the reverse order of removal.
7.5 FUEL FILTER MAINTENANCE
*KGE4000X / KGE6500X / KGE6500E models only
Step 1. Turn fuel tap to off position
Step 2. Remove inline fuel filter and inspect
To Clean Blow compressed air in opposite
direction of fuel flow
Step 3. Refit inline fuel filter
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Spark Arrestor
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