Kipor K DE2200X/E Maintenance Manual
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Kipor K DE2200X/E Maintenance Manual

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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

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  • Page 1 MAINTENANCE 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...
  • Page 2 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.
  • Page 3 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...
  • Page 4 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.

  • Page 5: Specifications

    1. SPECIFICATIONS 1-1 Main technical Specifications Generating Set...
  • Page 6 Generating Set Engine Generating set...
  • Page 7 Main technical specification of single-phase and three-phase generator sets Model KDE6500XW/EW KDE6700TW Rated frenquency (Hz) Rated output(kW) Rated output (V) Rated current(A) 12.2 12.5 12.2 12.5 Phase Single Single Poweer factor (cos ) Welding voltage at zero load(V) 70-75 60-65 Rated welding current(A) Welding work voltage(V) 25-35...
  • Page 8 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.
  • Page 9 (5)AC external characteristic curves of KDE6700T/TA generator sets 1-3 Overall dimension drawing Unit mm KDE2200X/E generator sets 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 KDE6700T/TA 120V 0 2 4 6 8 10 12 14 16 18 20 22 240V...
  • Page 10 KDE6500X/E/X3/E3 generator sets KDE6700T/TA/T3/TA3 generator sets KDE6500XW/EW generator sets KDE6500T/T3 generator sets...
  • Page 11 1-4 Wiring diagrams of: Voltmeter indicates 120V output Output KDE2200X/E generator sets Air switch Air switch Single voltoge output Output Air switch Low oil pressure protection Voltmeter Air switch Low oil pressure Low oil pressure protection indicator light Low oil pressure indicator light Main winding Main winding Output...
  • Page 12 Voltmeter indicates Output Breaker Sampling Black winding Output Yellow & Green Excitation winding Green Current White mutual-inducator Protection Low oil Yellow pressure switch Overloading Green Protect Black Yellow Start relay Main winding Main winding Blue Charging winding Sampling winding White Black Blue Start electric...
  • Page 13 Voltmeter indicates Output Air switch Brown Sampling Black Output winding Blue Air switch Yellow & Green Air switch Green White Protection Low oil Yellow pressure switch Black Start relay Blue White Black Blue Start electric motor Yellow & Green KDE3500E KDE6500E Double voltage simultaneous output, electric schematic diagram the same KDE3500T&KDE6500T generator sets Electric switch lock...
  • Page 14 KDE6700TA generator sets Fuse Blue irect current socket Blue Black Fuse Blue OFF-ON relationship list of electic switch lock Breaker Breaker Current mutual-inducator Breaker Direct current socket Black Current mutual-inducator Blue Black Single Single socket Black Black socket OFF-ON relationship list of electic switch lock Sampling Yellow&Green Sampling...
  • Page 15 KDE3500E3/T3 & 6500E3/T3 generator sets On-off relationship list of electric switch lock Blue Voltage selective switch Generating Brown winding Breaker Blue Brown Assistant winding Black Breake Sampling input Three-phases Breaker Main winding Excitation winding Black Yellow socket Yellow Sampling Green Green winding Low oil...

  • Page 16: Important Information

    Do not touch generator set with wet hands, otherwise, electric shock or circuit 2.4 Important safety precautions may happen. Kipor diesel generator sets are not rainproof, so please protect your generator set from rain, snow and water. Running at wet place may cause short Make sure you have a basic and complete understanding of safe operations.
  • Page 17 2.5 Service rules 2.6.8 Route and connect the wire harnesses properly. Be sure that the harnesses 2.5.1. Use Kipor recommended parts and lube or their equivalents, otherwise are not slack, twisted or pulled taut. engine may be damaged.
  • Page 18 2.7 Part name/description KDE6500T/KDE6500T3 - --KDE6700TKDE6700T3---KDE6700TA/KDE6700TA3 (KDE2200----6500E/X external parts) Fuel gavge Fuel tank cover Fuel tank Exhaust Fuel filter Fuse seat Volometer Cooling plate Hook Switch lock Air cleaner Air switch Handle Plug Air filtration Eareh bolt Starting handle cover Dc terminal Recoil starter Rubber...
  • Page 19 2.8 Serial number location Silent generator sets (KDE6500T/T3, KDE6700T/T3, KDE6700TA/KDE6700TA3 ): Befor open the set, look up, at the air guide plate at the front of the set. Serial number location varies according to generator set series: Open frame generator sets (KDE2200X/EKDE6500X/E----KDE6500EW/XW): at outer iron plate of generator stator, to be specifically, below fuel tank.
  • Page 20 2.9 The service standard for generating set 2.10 KDE6500EW/XW Resistance Standard value of Winding Set mode standard ( ) voltage at zero load (V) KDE2200X/E 1-1.5 230/240 Front end cover Hexagonal flange face bolt M8 25 KDE3500X/E 1.6-1.8 230/240 Rotor through bolt Hexagonal flange face bolt M10 210 KDE6500X/E...
  • Page 21 KDE6500T Hexagonal flange face nut Hexagonal flange face bolt M6 12 Front end cover Hexagonal flange face bolt M8 25 Hexagonal flange face bolt M5 12 Rotor through screw Hexagonal flange face bolt M10 210 Connecting wire of diverter Cross slotted pan head screw M4 10 Tighted bolt of fore/back end cover Hexagonal flange face bolt...
  • Page 22 KDE6700T KDE6500E Hexagonal flange face bolt M8X25 Front end cover Front end cover Hexagonal flange face bolt M8X25 Rotor through bolt Hexagonal flange face bolt M10X210 Hexagonal flange face bolt M10X210 Rotor through bolt Tighten bolt of fore/back end cover Hexagonal flange face bolt M6X140 Tighten bolt of fore/back end cover...
  • Page 23 KDE6500E KDE2200X/E Front end cover Front end cover Hexagonal flange face bolt M8X25 Hexagonal flange face bolt Rotor through bolt M10 225 Rotor through bolt Hexagonal flange face bolt M8X180 Tighten bolt of fore/back end cover Hexagonal flange face bolt M6 150 Tighten bolt of fore/back end cover Hexagonal flange face bolt...
  • Page 24 2.11 The set value for leaving the factory 2.11.2 The protecting setting values of the digital panel divide to: A The standard setting value of leaving factory 2.11.1 The set value of the automatic adjuster of the voltage AVR Low oil pressure protection: Protection by stopping if the oil pressure low for 5s, Output voltage is set as rated voltage;...
  • Page 25 2.12 Troubleshooting Open-shelf diesel engine and quiet generating set Fault Remedy: 2.12.1General symptom and possible cause Check the wiring harness. The lead-out of electric machine is loosened. Check or replace terminal. The four-port terminal of electric machine is cracked. Fault Remedy Open circuit of electric machine main winding coil Check resistance value at terminal, reconnect or replace stator.
  • Page 26 (2)Troubleshooting steps for no voltage 2.12.2 Flow Chart of Troubleshooting (Fig. Flow chart for diesel 2) (1)Troubleshooting steps for difficult starting of diesel engine set (Fig. Flow chart for Diesel 1) No voltage (No electricity generated) Difficult starting of failure to start Check gauging system in panel Circuit and battery section Oilway and fuel section...
  • Page 27 (3)Troubleshooting steps for failure to regulate voltage of diesel engine set (5)Troubleshooting steps for automatic stopping of diesel engine set (Fig. Flow chart for diesel 3) (Fig. Flow chart for diesel 5) Failure to regulate voltage Automatic stop Check the voltage on gauge panel for 300 or above Check that the engine oil alert system Add engine oil...
  • Page 28 Replace air cleaner element (Service more frequently when used in dusty areas) (Replace) KIPOR recommends CC/CD oil classified by API. Choose the applicable viscosity oil according to the local ambient temperature. Clean fuel oil filter (Replace) Series KDE, Type X/E Check fuel injection pump 3.2.3 Check air cleaner...
  • Page 29 3.2.4 Check Starting Performance of (3)Pull out the recoil starter handle. Pull out the handle until you feel the resistance, then return it back to the initial Generating Set position. Turn off the main switch and any other Press down the decompression lever. It will return automatically when the recoil loads.
  • Page 30 3.2.5 Check battery ATTENDED Only KDE6500T-6700T/TA generating set When the oil pressure is too low or the engine oil level is too low, the low oil is equipped a 12V36AH maintenance-free alerting system will act to stop the engine. If no engine oil is refilled, the battery as factory standard configuration.
  • Page 31 3.2.7 Check Overload Operation ATTENDED Electrical appliance particularly motor-driven equipment will produce very high Connect the positive and negative poles of the battery with the positive and current while starting, the table below provides the reference for connecting these negative poles of DC terminals separately. Do not confuse them, otherwise the apparatus to the generating set in service by user.
  • Page 32 3.2.8Check Stopping of Generating Set 4. MAINTENANCE (1)Disconnect the load from the generating set. 4.1 Oil-line and intake/exhaust parts (2)Turn off the air switch of the generating This section mainly deal with the actions which should be taken while a fault of set.
  • Page 33 4.1.4 Oil pipe/oil pump (2) Refill engine oil to specified position. (3) check the oil level again after fueling;if oil level is too low, fuel to specified level. (1) Check the oil pipe for deterioration, cracking, or leakage of diesel oil. If the oil (4) Reinstall the service cap.
  • Page 34 4.1.6 Muffler 4.1.5 Air cleaner a. Removing and reinstalling A dirty air cleaner will obstruct air from entering carburetor, thus reduces the Caution: Remove and reinstall the muffler after the engine is cooled down. engine working efficiency. If the engine is running in dusty area, clean the air (1)Protective hood of muffler cleaner more frequently.
  • Page 35 Service 1: The fault phenomena is no voltage output in generating set. Low-oil alert lamp Low oil alert lamp ----Receptacle terminal is loosened, receptacle terminal is melted. Voltmeter Voltmeter Cause: 1.Wring is loosened due to vibration. 2. Receptacle patchplug is loosened Electric to result in heating up switch...
  • Page 36 4.2.4 Voltmeter Check: Connect electric supply , which voltage range is the same as voltmeter, to the terminal post of voltmeter. The voltmeter should indicate normal voltage. Plug Service: Fault phenomena is that there is AC current output during generating set running, but no AC voltage indication.-----------The voltmeter is open-circuit, the Screw M6x12 wring of voltmeter is loosened.
  • Page 37 (3)Fix the rotor with a belt spanner, secure the 10MM flange bolt to specified 4.3 Generator torque. 4.3.1 Generator Tightening torque: 50 Nm (5.0 kgf.m, 37.5 lbf.ft) Check (1) Front end cover: Check for cracking 4.3.3 Stator (2) Generator fan: (Take care not to damage the fan blade in disassembling and If measured resistance exceeds above-mentioned specified value, check the assembling) harness of generator.
  • Page 38 Service: The fault phenomena is: no voltage, no power output, scrubbing of stator Cause: 1. Vibration 2. The sponge falls off by the effect of temperature. and rotor, generator burn-out, generating set does not start. Remedy: 1. Replace sponge. 2. Replace heat insulating material. Cause: 1.
  • Page 39 Cooling plate Left side plate Right side plate Cover plate of air cleaner (Fig.) Cabinet (1), (2), (3) Buoy sight window Shock pad Bolt M6x16 Fixing sheath for of oil tank sight window Bolt M6x16 Spring washer 6 Bolt M6x16 Big washer 6 Rear door weldment Bolt M6x16...
  • Page 40 5. SERVICE OF INTELLIGENT CONTROL PANEL Charging checkout, negative Charing checkout, position Common terminal fur output Common terminal for output Starting output Stating output Fuel oil control output Power supply input Engine oil alarming input(grounding is valid) Power supply input, positive Voltage selection 120/240 Protection input(low is valid) Starting signal (high is valid)
  • Page 41 5.1 Setting (7) Press and hold down key "FUN", Turn the electric switch lock from OFF to ON. After 5 seconds enter setting program. Start generating set. The protection function for electrical (1) Press and hold down key "FUN", turn the electric switch lock from OFF to parameters will be revoked ON.
  • Page 42 5.3 Maintenance Press key FUN, the current (power) indicating lamp will on. The output current Fault code display and actions to be taken (factory default) (power) is displayed in display window. According to different phase number of output display current (power) as follows: Meaning Action to be taken Code display...
  • Page 43 Fault code display and actions to be taken (default for 5 KW special requirement Note: in North America) (1) At protection of generating set the protected object and protection code are displayed alternately in display window. Meaning Action to be taken Code display Remark (2) When protection stopping happens, you can press key FUN to inquire the...
  • Page 44 5.5 Diagram of Switch Position for Address Setting...

This manual is also suitable for:

K de5000x/e/tK de6500x/e/t/taK de6700t/taK da6700ta/taoK de6500x3/e3/t3K de3500x/e/t ... Show all

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