Kipor IG3000 Installation manual

Preface
Thank you for purchasing KIPOR diesel generator set.
This instruction includes the operations and maintenance of IG3000 and IG4000.
This instruction is written according to the newly developed products.
KIPOR has the right to modify this instruction without further notice.
No duplicating without written approval.
As a part of the generator, this instruction should be transferred accompanying the
generator.
Please pay particular attention to the following signs:
Failure to properly follow these precautions may result in
property damage, serious injury or DEATH!
Read all labels and the owner's manual before operating
this generator.
Operate only in well ventilated areas. Exhaust gas contains
poisonous carbon monoxide, and can be deadly. Always
stop engine before refueling. Wait 5 minutes before
restarting.
Check for spilled fuel or leaks. Clean and/or repair before
use.
Keep any sources of ignition away from fuel tank, at all
times.
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, consult an authorized dealer.
Our generators are 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.

Content
1. Safe use instruction ···························································································1
2. Parts identification ····························································································3
3. PRE-OPERATION CHECK················································································8
4. Starting engine·································································································12
5. Generator use··································································································15
6. Stop the Engine ·······························································································19
7. Maintenance ····································································································20
8. Transportation/Storage·····················································································25
9. Troubleshooting ·······························································································26
10. Basic parameters···························································································28
11. Electric schematic diagram ············································································30
12. Castor Assembly ····························································································33
13. Appendix ········································································································35

1
1. Safe use instruction
Operate carefully and make sure users and others safety.
WARNING
■Our generators are 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.
WARNING
■Never run the generator in an enclosed area for exhaust
gas contains poisonous carbon monoxide. Be sure to
provide adequate ventilation.
WARNING
■ The muffler becomes very hot during operation and
remains hot for a while after stopping the engine.
Be careful not to touch the muffler while it is hot.
■ To prevent scalding, please pay attention to the warning
marks attached to the generator.

2
WARNING
■Gasoline is extremely flammable and explosive under certain conditions. Refuel
in a well ventilated area with the engine stopped.
■Keep away from cigarette, smoke and sparks 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.
WARNING
■Connections of communication base station standby power and its electrical
system must be made by a qualified electrician and must comply with all applicable
laws and electrical codes.
WARNING
■ Always make a pre-operation inspection before you start the engine. You may
prevent an accident or equipment damage.
■ Please operate the generator at outdoor or under good ventilation condition.
■ Operate the generator on a level surface. If the generator is tiled, fuel spillage
may result.
■ 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.
■Keep away from the exhaust outlet 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 and do not let it get wet.

3
2. Parts identification
2.1 Outside overview
See Fig.1.
Fig.1 Outside view

4
Oil level switch
2.2 Control panel
2.2.1 IG3000 Control panel
See Fig. 2
Fig.2 IG3000 Control panel
油开关
空滤盖
IG4000 oil level
switch
A
ir filter cove
r

5
2.2.2 IG4000 Control panel
See Fig.3 and Fig.4
(1) IG4000 single-voltage control panel
Fig.3 IG4000 single-voltage control panel
(2)IG4000 dual-voltage control panel
Fig. 4 IG4000 dual-voltage control panel

6
2.3 SMART Energy-saving switch
ON：
Generator would be at idle state if electrical appliance is disconnected from engine;
Engine would return to normal speed once connected with appliance. This equipment
is to reduce oil consumption in running.
CAUTION
■ (SMART) energy saving switch cannot run effectively when greater instant
power is needed.
■ Shut down energy saving switch to reduce voltage variation when generator is
connected with high electrical load.
■ Close energy saving switch during DC operation.
OFF：
Indicates that smart energy saving switch is closed and engine is at high rotation
speed.
2.4 LCD parameters display
2.4.1 Single-voltage LCD－230V
LCD will display the following parameters in cycle
after powered on:
No. Parameters Unit Note
1 Genset voltage 1 V V
1 A
2 Genset current 0.1 A A
3 Genset frequency 0.1 Hz Hz
4 Battery voltage 0.1 V V
5 Accumulated running time 0.1 Hour Hr
CAUTION
■LCD back light lights for 10 seconds then goes out automatically once pushed
button.
■When the current displayed parameter is not “genset voltage”, displayed
parameter will switch to “genset voltage” automatically after 30 seconds.

7
2.4.2 Dual-voltage LCD－120/240V
After the system is powered on, self-check indicator lights and buttons are pushed
continually, the following parameters will be displayed in cycle:
(1) Displayed parameters in series connection：（120/240V simultaneous output）
No. Parameters Unit Note
1 Genset AB-Phase voltage 1 V V
2 Genset A-Phase voltage 1V V
3 Genset B-Phase voltage 1V V
1 A
4 Genset A-Phase current 0.1 A A
1 A
5 Genset B-Phase current 0.1 A A
6 Genset frequency 0.1 Hz Hz
7 Battery voltage 0.1 V V
8 Accumulated running time 0.1 Hour Hr
(2) Displayed parameters in parallel connection:（120V output）
No. Parameters Unit Note
1 Genset voltage 1 V V
1 A
4 Genset current 0.1 A A
6 Genset frequency 0.1 Hz Hz
7 Battery voltage 0.1 V V
8 Accumulated running time 0.1 Hour Hr
CAUTION
■ LCD back light lights for 10 seconds then goes out automatically once pushed
button.
■ When the current displayed parameter is not “genset voltage”, displayed
parameter will switch to No.1 listed parameters after 30 seconds.
■ Parameter will be displayed as“――――――” when voltage selection switch is at
incorrect position.

8
3. PRE-OPERATION CHECK
Be sure to check the generator on a level surface with the engine stopped.
3.1 Check the engine oil level.
CAUTION
■Using no detergent oil or 2-stroke engine oil could shorten the engine's service
life.
■Use 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 temperature in your area
SAE Viscosity Grades
Ambient Temperature Oil Number
-25℃-30℃10W-30
-15℃-40℃15W-40
Open the left side oil maintenance cover. 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. If the oil level is below the end of the dipstick, refill with
recommended oil up to the top of the oil filler neck, see Fig 3.
Fig.5 Oil level

9
CAUTION
■Running the engine with insufficient oil can cause serious engine damage.
■The Low Oil Alarm 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.
3.2 Check the fuel level
Use automotive gasoline (Unleaded or low-leaded is preferred to minimize
combustion chamber deposits).
If the fuel level is low, refill to the shoulder of the fuel strainer, see fig. 4.
Never use an oil/gasoline mixture or dirty gasoline.
Avoid getting dirt, dust or water in the fuel tank.
After refueling, tighten the fuel filler cap securely.
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
flame 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 in the filler neck). After
refueling, make sure the fuel filler 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 vapor. KEEP OUT
OF REACH OF CHILDREN.
Fuel tank capacity: 13L
Fig.6The fuel level

10
Gasoline containing alcohol
If you decide to use a gasoline containing alcohol (gasohol), be sure its octane rating
is at least as high as that recommended by us. There are two types of "gasohol": one
containing ethanol, and the other containing methanol. Do not use gasohol that
contains more than 10% ethanol. Do not use gasoline containing methanol (methyl or
wood alcohol) that does not also contain cosolvents and corrosion inhibitors for
methanol. Never use gasoline containing more than 5% methanol, even if it has
cosolevents and corrosion inhibitors.
NOTE
■Fuel system damage or engine performance problems resulting from the use of
fuels that contain alcohol is not covered under the warranty. We cannot endorse the
use of fuels containing methanol since evidence of their suitability is as yet
incomplete.
■Before buying fuel from an unfamiliar station, try to find out if the fuel contains
alcohol, if it does, confirm the type and percentage of alcohol used. If you notice
any undesirable operating symptoms while using a gasoline that contains alcohol,
switch to gasoline that you know does not contain alcohol.
3.3 Check the air cleaner
Check the air cleaner elements to be sure they are clean and in good condition.
Open the left side maintenance cover. Remove the air cleaner cover, remove the
paper element from the air cleaner cover, and check the both elements, clean or
replace the element(s) if necessary, see fig.7.

11
Fig. 7 Structure of air cleaner
CAUTION
■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.

12
4. Starting engine
CAUTION
■When starting the generator after adding fuel for the first time, after long-term
storage, or after running out of fuel, turn the fuel valve lever to the "ON" position,
then wait for 10 to 20 seconds before starting the engine.
4.1 IG3000 starting order:
(1) Open the fuel valve first, see fig.8.
Fig.8 Fuel valve lever to the ON position
(2) Pull the choke knob out to the CLOSED position
Do not use the choke when the engine is warm or the air temperature is high, see
fig.9
Fig.9 Choke knob to the closed position

13
(3) Insert the engine key and turn the engine switch to ON position.
See fig.10
Fig.10 Starting button to the ON position
(4) Starting
Electric start: Pull the engine switch to the START until the engine is started. See
fig.11 (a)
Manual start: Pull the starting handle until resistance is felt. Pull quickly in the
direction showed in the following diagram. See fig.11 (b).
Fig.11 (a) Engine Fig.11 (b) Starting handle
CAUTION
■Keep the starting handle from rebounding and slowly put the handle in order.
■Keep the starting handle away from rubbing generator or handle would be
damaged.

14
(5) Push the choke knob to the OPEN position as the engine warms up, see Fig. 12.
Fig.12 The open position of Choke knob
(6) After normal starting, the genset can be loaded.
4.2 IG4000 starting order：
(1) Break the load and turn the breaker to “OFF” position.
(2) Start genset according to the step 2, 3, 4 and 5 of IG3000 starting order.
(3) After normal running of genset, connect load and turn the breaker to “ON” position.
High altitude operation
At high altitude, the standard carburetor air-fuel mixture will be excessively rich,
engine performance will decrease and fuel consumption will increase.
High altitude performance can be improved by installing a smaller diameter main fuel
jet in the carburetor and readjusting the pilot screws. If you always operate the
generator at altitude higher than 1,500 m (5,000 feet) above sea level, have your
authorized dealer perform these carburetor modifications.
Even with suitable carburetor jetting, engine horsepower will decrease approximately
3.5% for each 305 m (1.000 feet) increase in altitude. The effect of altitude on the
horsepower will be greater than this if no carburetor modification is made.
CAUTION
■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.