Kipor IG6000 User manual

IG6000
IG6000h
Generator Service Manual
The Coast Distribution System, June 1, 2007

Preface
This manual covers the construction, function and servicing procedure of the Coast Distribution System
KIPOR IG6000 model generator. This manual is principally concerned with the generator specifications,
function, troubleshooting and repair. There is a separate manual to cover engine overhaul which
includes the starting systems.
These models may be of significantly different design than the original KGE7000Ti and other models
currently sold outside NorthAmerica. Contact Kipor for current service information.
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.........................................................................................................................................1
1.1 General Specifications..................................................................................................................1
1.2 Generator Specifications2..............................................................................................................2
1.3 Performance Curves......................................................................................................................3
1.4 Wiring Diagram..............................................................................................................................4
2. Service and Maintenance ……………………………………………………………………………………. 5
2.1 The Importance of Proper Service.……………………………………………………………………...5
2.2 Safety Precautions.…………………………………………………………………………………….....5
2.3 Service Rules.................................................................................................................................6
2.4 Electrical Precautions......……………………………………………………………………………......7
2.5 Serial Number and Bar Code Location..........................................................................................7
2.6 Alternator Service Standards.…………………………………………………………………………....8
2.7 Fastening Torques.………………………………………………………………………………………..8
2.8 Troubleshooting.…………………………………………………………………………………………..9
2.8.1 General Symptoms and Repair ……………………………………………………………….....9
2.8.2 Hard Starting or No Start .....................................................................................................9
2.8.3 Ignition System …………………………………………………………………………………..10
2.8.4 Low Oil Level Alarm .……………………………………………………………………………..11
2.8.5 Engine Speed Problems .………………………………………………………………………..11
2.8.6 Engine Stops After Starting.……………………………………………………………………..12
2.8.7 Throttle Control System......................................................................................................12
2.8.8 Low AC Output. …………………………………………………………………………………..13
2.8.9 No AC Output.…………………………………………………………………………………….13
2.8.10 Electric Starter. ………………………………………………………………………………....14
2.8.11 Battery Charging...............................................................................................................14
3. Inspection and Adjustment...................................................................................................................15
3.1 Maintenance Schedule.................................................................................................................15
3.2 Engine Oil.....................................................................................................................................15
3.3 Low Oil Level Switch .................................................................................................................17
3.4 Air Cleaner....................................................................................................................................17
3.5 Spark Plug....................................................................................................................................18
3.6 Valve Clearance. ......................................................................................................................... 19
3.7 Fuel Switch/Fuel Filter................................................................................................................. 20
4. Air Cleaner/Muffler...............................................................................................................................21
4.1 Air Cleaner....................................................................................................................................21
4.2 Muffler...........................................................................................................................................21
5. Carburetor ...........................................................................................................................................22
5.1 Disassembly and Reassembly......................................................................................................22
5.2 Stepping Motor/Fuel Shutoff Solenoid..........................................................................................23
6. Control Panel and Inverter Module......................................................................................................24
6.1 Disassembly and Reassembly.....................................................................................................24
6.2 AC Receptacles............................................................................................................................24
6.3 DC Receptacle.............................................................................................................................24
6.4 Smart Throttle Switch...................................................................................................................24

6.5 Ignition Module.............................................................................................................................24
6.6 Ignition Switch..............................................................................................................................25
6.7 Bridge Rectifier.............................................................................................................................25
6.8 Charge Regulator.........................................................................................................................26
6.9 Timing Relay.................................................................................................................................26
6.10 Ignition Control Module...............................................................................................................27
6.11 Inverter Module...........................................................................................................................27
7. Frame, Housing, and Fuel Tank...........................................................................................................28
7.1 Disassembly and Reassembly......................................................................................................28
7.2 IG600h Handle Assembly.............................................................................................................29
8. Ignition Coil, Trigger, Alternator............................................................................................................30
8.1 Component Identification..............................................................................................................30
8.2 Ignition Coil and Trigger................................................................................................................31
8.2.1 Disassembly and Reassembly...........................................................................................31
8.2.2 Inspection...........................................................................................................................31
8.3 Alternator......................................................................................................................................33
8.3.1 Disassembly and Reassembly...........................................................................................33
8.3.2 Inspection...........................................................................................................................33

1
1．SPECIFICATIONS AND DIAGRAMS
1.1 General Specifications
Dimensions and weights
Model
IG6000
IG6000H
Overall length- in. (mm)
31.6 (802)
48.6 (1235)
Overall width- in. (mm)
19.5 (498)
25.6 (650)
Overall height- in. (mm)
24.6 (624)
30.3 (770)
Dry weight- lbs. (Kg)
209 (95)
223 (103)
Engine
Model
KG390GETi
Type
4-stroke,OHV, single cylinder
Displacement- cu.in. (cc)
23.7 (389)
Bore x stroke- in. (mm)
3.46 x 2.51 (88×64)
Maximum horsepower(KVA)
7.7/3600
Compression ratio
8.5:1
Cooling system
Forced air
Ignition system
Transistorized controlled ignition
Ignition timing
28°B.T.D.C
Spark plug
F7RTC
Carburetor
Horizontal float type
Air cleaner
Dry replaceable element
Governor
Inverter module control
Lubrication system
Forced splash
Oil capacity- qt. (L)
1.2 (1.1)
Starting system
Electric starter
Stopping system
Electric ground
Fuel
Automotive unleaded gasoline 87 octane
Generator
Model
KD50
Generator type
Multi pole rotation type
Generator structure
Self-ventilation drip-proof type
Excitation
Self-excitation (Magnet type)
Voltage regulation system
Pulse Width Modulation
Phase
Three phase
Rotating direction
Clockwise (Viewed from the generator)
Frequency regulation
AC-DC-AC conversion (Inverter type)

2
1.2 Generator Specifications
Model
IG6000
Maximum output（AC）
6.0 KVA
Rated output (AC)
5.5 KVA
Rated frequency (HZ)
60
Rated voltage（AC）
120/240
Maximum current (amp)
25/50
Rated current（amp）★
23.9/45.8
Rated voltage（DC）
12V
Rated current（DC）
12A
Power factor
1.0
Voltage variation
rate
Momentary
Max.10%
Average
Max.1.5%
Average time
Max. 3 seconds
Voltage stability
±1%
Frequency
variation rate
Momentary
Max. .5%
Average
Max. .5%
Average time
Max. .05 second
Frequency stability
±0.1%
Insulation resistance
Min. 10MΩ
AC circuit protector- Amps 120/240 VAC
51.7/25.8
DC circuit protector
15A
Fuel tank capacity- gal (L)
5.9 (22)
Operating hours at rated load
6
Noise level dB @23’ (7 m) no load-full load
63~70

3
1.3 PERFORMANCE CURVES
The curves show performance of the generator under average conditions. Performance may vary
depending upon ambient temperature, altitude and humidity.
●AC External characteristic curves
●DC External characteristic curves

4
1.4 Wiring Diagram

5
2. SERVICE AND MAINTENANCE
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 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.

6
2.3 Service Rules
Use genuine KIPOR or KIPOR recommended parts and lubricants or their equivalents. Parts that
do not meet Kipor’s design specifications may damage the engine and void the warranty.
Use special tools designed for the product when specified.
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 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.

7
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 manufacturer’s
operating instructions carefully before operating the tester. Be sure that the tester battery is fully
charged and the meter is functioning properly
2.5 Serial Number and Bar Code Location
The engine serial number is stamped beside the engine oil drain plug. This number is used to identify the
specific engine version.
Engine serial number
The bar code is used by Coast Distribution to determine production date and warranty administration.
The bar code is found in three locations:
on the generator, on the packing carton
and on the inside cover of the
operator’s manual.

8
2.6 Alternator Maintenance Standards
Part
Item
Type
Standard（Ω）
Service
limit
120V/240V
Ignition winding l
Resistance
Orange－
Yellow/Green
0.22~0.24
Gray－orange
0.15~0.17
External charging
winding
Resistance
Blue－blue
0.03~0.04
Built-in charging
winding
Resistance
Purple－Purple
0.12~0.16
Sub winding
Resistance
White－white
(green－green)
0.08~0.12
Main winding
Resistance
Black－black
(red－red)
0.45~0.60
0.09~0.10
0. 9~1.1
2.7Fastening Torques
Item
Specification
Tightening torque
Ft lb.
N.m
Connecting rod bolt
M8
14.8~16.3
20~22
Cylinder cover bolt
M10×1.25×80
31.0~34.0
42~46
Spark plug
M14×1.25×19
18.4~22.2
25~30
Crankcase side cover
bolt
M8×30
14.8~17.0
20~23
Rotor nut
M18×1.5
88.5~95.9
120~130
Rocker arm shaft bolt
M8×16
14.8~17.0
20~23
Adjusting nut of rocker
arm shaft
M6×0.75
7.8~8.8
10~12
Standard torque
M5 bolt、nut
4.4~5.9
6~8
M6 bolt、nut
5.9~7.4
8~10
M8 bolt、nut
14.8~17.0
20~23
M10 bolt、nut
40.6~44.3
55~60
Note: Use standard torque values for fasteners that are not listed in this table.

9
2.8 Troubleshooting
This section gives very general information regarding symptoms and possible causes. Refer to
subsequent sections regarding testing and removal and replacement of specific components and
systems. Engine overhaul is addressed in the IG6000 Engine shop manual.
2.8.1 General symptoms and possible causes
Engine does not
start or hard
starting
Fuel filter clogged
Clean
Fuel hose clogged
Clean
Fuel switch won’t operate
Replace
Carburetor defective
Clean and/or replace
Ignition coil defective
Inspect and replace
Spark plug defective
Inspect and replace
Defective timing relay
Inspect and replace
Trigger defective or improper air gap
Inspect and replace
Spark plug cap disconnected
Install securely
Oil level alarm defective
Inspect and replace
Ignition coil defective
Inspect and replace
Valve clearance misadjusted
Adjust valves
Engine speed
does not stabilize
Carburetor faulty
Clean and/or replace
Throttle control motor (stepping motor)
defective
Inspect and replace
Inverter unit defective
Inspect and replace
Valve clearance misadjusted
Adjust valves
2.8.2 Hard starting or no start
Check the fuel level in the tank
→no fuel
Add fuel and restart the engine
↓Sufficient fuel
Check fuel switch is in ON position
→off
Turn on it and restart the engine
↓on
Loosen the drain screw and check
whether fuel reaches bowl and whether
the fuel level is normal
→abnormal
Check fuel system for blockage
↓normal
Remove and check spark plug and check
if electrode is wet or dry
→dry
Check carburetor for fuel delivery
↓wet
→
Clean and dry the carburetor and observe
choke action. is severe, check if any fuel
leakage and if the floating valve is normal

10
Attach the spark plug on plug cap, ground
the electrode on the cylinder head.; start
the engine and check the spark conditions
→no spark
or weak
spark
Perform the ignition system troubleshooting
↓normal
Install a compression gauge in the spark
plug hole and restart the engine and
check the cylinder compression
→low
cylinder
compression
1. Check valve clearance;
2. check cylinder head gasket for leakage
3. Check combustion chamber for excess
carbon buildup
4. check valve seats and guides
5. check for worn piston, piston rings and
cylinder
↓normal compression (80 psi/.55 Mpa)
Install the spark plug. Restart the engine
according to the starting procedure.
2.8.3 Ignition system troubleshooting
■Spark plug inspection
1. Remove spark plug
2. Attach the removed spark plug to the plug cap
3. Ground the negative electrode of the spark plug against the cylinder head or engine block and engage
the electric starter and check to see if a spark jumps across the electrode.
Measure the spark plug gap and perform
the spark test.
Standard gap: .028-.034 in. (0.7-0.8 mm)
↓no spark
Perform the spark test again using a new
spark plug
→normal
spark
Replace the spark plug
↓no spark
Perform the spark test again using a new
spark plug
→normal
spark
Replace Ignitor
↓no spark
Check ignition module
→abnormal
Replace the ignition module
↓normal
Check resistance of ignition coil
→abnormal
Replace the coil
↓normal
Check trigger air gap and trigger
resistance
→abnormal
Adjust the air gap and/or replace the
trigger
↓normal
Check the ignition coil resistance and high
voltage cable and insulation cap
→abnormal
Check the ignition coil
↓
Check or replace wiring harness

11
2.8.4 Engine oil level is low, but engine does not stop.
Drain out all engine oil, disconnect the
low oil alarm wire and check if the outlet
terminal is connected to ground
→not
conductive
Replace the oil level alarm switch
↓conductive
Connect the alarm wire, loosen ignition
module receptacle and check if the
orange wire is connected with the ground
→not
conductive
Repair wiring harness
↓conductive
Replace ignition module
2.8.5 Engine speed does not increase or is unstable
Check choke for proper operation
↓ OK
→abnormal
Adjust/repair choke mechanism
Check the air cleaner
→clogged
Clean or replace air cleaner
↓not clogged
Check the valve clearance
→abnormal
Adjust the valve clearance
↓normal
Remove the spark plug and check the
electrodes for carbon and spark plug gap
→abnormal
Clean the spark plug and adjust the spark
plug gap or replace new spark plug
↓normal
Check for blockage of the main jet
→clogged
Disassemble and clean or replace
carburetor
↓not clogged
Check the air intake gasket and the
sealing of heat-insulation block of
carburetor
→abnormal
Tighten the nuts securely, replace the
gasket or heat-insulation block
↓normal
Perform the cylinder compression check
→abnormal
1. Check the valve clearance
2. Check combustion chamber for excess
carbon
3. Check the piston, piston ring and
cylinder for wear and damage.
↓normal
Perform the throttle control system
troubleshooting

12
2.8.6 Engine stops after starting
Check the engine oil level and check if
oil level alarm activates when rotation
stops
→oil level
alarm
Add oil and restart the engine
↓sufficient oil
Check the fuel in fuel tank
→no fuel
Add fuel and restart the engine
↓sufficient fuel
Check for operation of fuel switch and
blockage in fuel filter
→clogged
Clean the fuel switch and filter
↓not clogged
Check for blockage of fuel hoses
→clogged
Clean or replace the hoses
↓not clogged
Check for carburetor fuel delivery
→not
fueling
Disassemble and clean
↓normal fuel flow
Check the intake gasket and the sealing
of carburetor heat-insulation block
→abnormal
Tighten the nuts securely, replace the
gasket or heat-insulation block
↓normal
Measure the cylinder compression
→abnormal
1. Check the valve clearance
2. Check if too much carbon in burning
room
3. Check the piston, piston ring and
cylinder for wear and damage.
↓normal
Check the trigger air gap
→abnormal
Readjust the clearance
↓normal
Perform throttle control system
troubleshooting
2.8.7 Throttle control system
a. Engine speed is too high
Check AC output
abnormal
Perform the generator troubleshooting
flowing the instruction of “No or Low AC
output”
↓normal
Check the stepping motor
→abnormal
Replace the stepping motor
↓normal
Replace the inverter unit
b. The engine speed does not increase when smart throttle is on and load is increased.
Check the AC output
→abnormal
Perform the generator troubleshooting
flowing the instruction of “No or Low AC

13
output”
↓normal
Check the stepping motor
→abnormal
Replace the stepping motor
↓normal
Check the smart throttle switch
→abnormal
Replace the smart throttle switch
↓normal
Check “Smart” switch wire
→abnormal
Repair or replace the wire harness
↓normal
Replace the inverter unit
2.8.8 Low AC output
Is the overload indicator light ON?
→on
Disconnect the load, and restart the engine.
↓off
Is the engine speed normal?
Smart switch operation:
On: 2500±100rpm
Off: 3600±100rpm
→abnormal
Perform the throttle control system
troubleshooting
↓normal
Check the AC receptacle
→abnormal
Replace the receptacle
↓normal
Check the AC output connector
→abnormal
Replace the connector
↓normal
Disconnect the two 4P input connectors
on the inverter unit. Disconnect spark
plug cap or igniter connector, and
measure the AC voltage of from the
stator. The output voltage across pins
1-2, 2-3, and 1-3 should be 255 volts.
Check both connectors.
→abnormal
1. Check the wiring of the stator leads in
the harness. Repair or replace the
harness.
2. Replace the alternator.
↓normal (255 volts)
Replace inverter unit
2.8.9 No AC output
Is the engine speed normal?
abnormal
Perform the throttle control system
troubleshooting
↓normal
Check AC receptacles
→abnormal
Repair wiring or replace receptacles2.7.9
↓normal
Check the rectifier
→abnormal
Replace the rectifier
↓normal
Measure the resistance between two
blue wire on the rectifier
Resistance:0.03~0.04Ω
→abnormal
Check and repair the wire harness or
replace the stator
↓normal
Rotor losses excitation, replace the rotor

14
2.8.10 Electric Starter
Check the battery voltage
→abnormal
Charge or replace the battery
↓normal
Check ignition switch
→abnormal
Replace the ignition switch
↓normal
Check the ignition relay
→abnormal
Replace ignition relay
↓normal
Check the starting motor
→abnormal
Replace the starting motor
↓normal
Check and repair or replace main wire
harness
2.8.11 The battery will not charge or maintain a charge
Check ignition switch
→abnormal
Replace ignition switch
↓normal
Check charging regulator
→abnormal
Replace the charging regulator
↓normal
Measure resistance of charging coil
winding
Resistance: 0.12~0.16Ω:
→abnormal
Check and repair electric wire harness or
replace stator.
↓
Check and repair or replace wire harness

15
3. INSPECTION AND ADJUSTMENT
3.1 MAINTENANCE SCHEDULE
Regular service period(1)
Item perform at every indicated
month or operating hour interval,
whichever comes first
Project
Each use
Each
month or
every 10
hours
Every 3
months
or every
50 hours
Every 6
months or
every 100
hours
Every year
or every
300 hours
Engine Oil
Check
●
Replace
●
●
Air cleaner
Check
●
Replace
●*
Spark plug
Clean-Adjust
●
Spark Arrestor
Clean
●
Valve clearance
Check-Adjust
●**
Fuel tank and filter
Clean
●**
Fuel line
Check
Every 2 years and replace if necessary
Note:
* Service more often in dirty dusty conditions
** Should be performed by trained service center personnel
3.2 Engine oil
●Checking the oil level
Stop the engine and check the oil level, be sure to put the engine on a flat floor when checking.
（1）Remove the oil dipstick and check the level.
Lower limit
Upper limit
（2）If the oil level is low, add to the edge of the oil filler port (upper limit).
● Engine oil change
（1）Remove dipstick and oil drain bolt and drain out the used oil.
（2）Tighten the oil drain bolt securely.

16
（3）Pour the specified amount of fresh engine oil through the oil filler port.（Engine oil capacity : 1.2 qt
(1.1L)
※Recommended engine oil：
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 temperature in your area.
SAE Viscosity Grades
（4）After refilling, check the oil level again..
（5）Tighten the dipstick.
● drain the used oil while the engine is warm. Warm oil drains quickly and completely.
●please dispose of the used motor oil in a manner that is compatible with the environment. We suggest
you take used oil in a sealed container to your local recycling center or service station for reclamation.