Kipor IG1000 Shop Manual
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Kipor IG1000 Shop Manual

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KIPOR POWER PRODUCTS CO., LTD.
IG1000 SHOP MANUAL
EPA/CARB/CETL Certified Models
 
    
 
 
 
 
 
 
 
 
Kipor Power Systems, Inc.
Revision 4, July, 2011 

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  • Page 1                                   KIPOR POWER PRODUCTS CO., LTD. IG1000 SHOP MANUAL EPA/CARB/CETL Certified Models                        Kipor Power Systems, Inc. Revision 4, July, 2011 ...
  • Page 2 UXI 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.

  • Page 3: Table Of Contents

    CONTENTS 1. SPECIFICATIONS/WIRING DIAGRAM ..................1 1.1 SPECIFICATIONS ......................1 1.2 WIRING DIAGRAMS ......................3 2. SERVICE INFORMATION ......................6 2.1 THE IMPORTANCE OF PROPER SERVICING ..............6 2.2 IMPORTANT SAFETY PRECAUTIONS ................6 2.3 SERVICE RULES ....................... 5 2.4 ELECTRICAL PRECAUTIONS ................... 7 2.5 SERIAL NUMBER AND BARCODE ..................
  • Page 4 7. CONTROL PANEL ........................ 32 7.1 REMOVAL AND INSTALLATION ..................33 7.2 INSPECTION ........................33 8. HOUSING/FUEL TANK ......................35 8.1 HOUSING DISASSEMBLY ....................35 8.2 FUEL TANK ASSEMBLY ....................36 9. RECOIL STARTER/AIR CONDUCT COVER/IGNTION COIL/AIR CONDUCT PLATE ..37 9.1 DISASSEMBLY AND REASSEMBLY ................
  • Page 5 This page intentionally blank...

  • Page 6: Specifications/Wiring Diagram

    1. SPECIFICATIONS and WIRING DIAGRAM 1.1 SPECIFICATIONS Dimensions and weights Model IG1000/IG1000P Overall Length in (mm) 18.1 (460) Overall Width in (mm) 9.8 (248) Overall Height in (mm) 15.6 (395) Net Weight in (Kg) 30.8 (14) Engine Model KG144 Type 4-stroke,OHV, single cylinder, Gasoline engine Displacement cu in.
  • Page 7 Performance Model IG1000 Maximum output AC 1.0KVA Rated output AC 0.9KVA Rated output DC 100W Rated frequency 60HZ Rated voltage AC 120V Rated voltage DC Rated current AC 7.5A Rated current DC 8.3A Power factor Voltage variation rate Momentary 10%max.
  • Page 8 1.2 WIRING DIAGRAM IG1000 through 2010 Model Year...
  • Page 9 IG1000 2011 Forward...
  • Page 10 IG2000P 2011 forward...

  • Page 11: Service Information

    2. SERVICE INFORMATION 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.

  • Page 12: Service Rules

    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. • Use the special tools designed for the product. • Always install new gaskets, O-rings, etc. when reassembling components.
  • Page 13 • 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. •...

  • Page 14: Maintenance Standards

    2.6 Maintenance standards Part Item Standard(mm) Service limit Engine Maximum speed without load 5500±100 rpm — 1.712-1.714 in 1.716 in Cylinder Sleeve I.D. 43.500-43.520 mm 43.595 mm 1.711-1.712 in 1.707 in Skirt O.D 43.460-43.480 mm 43.350 mm Piston 0.3937-0.3940 in 0.3955 in Pin bore I.D.

  • Page 15: Torque Values

    3.965—3.980 mm 3.900 mm 0.1557-0.1562 in 0.1540 in Exhaust 3.955—3.970 mm 3.900 mm 0.1575-0.1579 in 0.2598 in Guide I.D. IN/EX 4.000—4.012 mm 4.060 mm 0.925 in 0.866 in Valve spring Free length IN/EX 23.5 mm 22 mm 1.101-1.103 in 1.062 in Cam wheel Cam height 27.97-28.03 mm...

  • Page 16: Troubleshooting

    3. Troubleshooting This troubleshooting section contains troubleshooting trees organized by common groups of symptoms. Some testing information is contained in these sections. The following chapters of this manual focus on individual components and sub assemblies which will give you the assembly and reassembly procedures along with detailed specifications and testing procedures.

  • Page 17: Hard Starting

    3.2 Hard starting No fuel Check the fuel level in the tank. Add fuel and restart the engine. Sufficient fuel Loosen the drain screw and Abnormal Check the fuel lines for blockage. check whether fuel reached the float chamber and the oil level. Normal Check for blockage in the carburetor Remove the spark plug and...
  • Page 18 C. Ignition system ■ Fill in oil to the required level. ■ Use spark plug UR5. ■ Spark plug inspection 1. Disassemble spark plug 2. Install spark plug onto spark plug cap. 3. Set the oil switch to the “ON” position. Ground the negative (—) electrode (i.e. threaded part) of the spark plug against the shroud and pull the recoil starter rope to check the spark plug.
  • Page 19 3.2 Hard Starting Continued Measure the spark plug gap and perform the spark plug test. Gap: 024-028 in (0.6—0.7mm) No spark Good spark Perform the spark test again using a Replace the spark plug new spark plug No spark Good spark Remove the control panel.

  • Page 20: Engine Stops Running

    3.3 Engine oil level is low, but engine does not stop. (Defective oil switch) Drain out oil completely, disconnect alarm No continuity connection wire, and check the continuity Replace the oil level alarm between alarm outlet terminal and ground. Continuity Reset the alarm connection wire, disconnect No continuity Repair or replace the wire...

  • Page 21: Engine Speed Too High Or Low

    3.5 Engine speed can’t increase or unstable (choke is at the correct position) Blocked Check the air filter element for blockage Clear the air filter element No blocked Abnormal Check the valve clearance Readjust the valve clearance Normal Remove the spark plug and check the Abnormal Clear electrode, adjust clearance electrode clearance for carbon deposit...

  • Page 22: Smart Throttle

    3.7 Smart system doesn’t work with zero load or engine speed doesn’t increase with Smart system on and load connected. Perform the generator Abnormal Check the AC output troubleshooting following the section on “No AC or low voltage” Normal Abnormal Check the throttle control motor Replace the throttle control motor Normal...

  • Page 23: No Dc Output

    3.9 No DC output Abnormal Perform the throttle control system Check the engine speed troubleshooting Normal Abnormal Check the DC receptacle Replace the DC receptacle Normal Abnormal Check the 5 amp fuse Replace the fuse Normal Abnormal Check the rectifier Replace the rectifier Normal Measure...

  • Page 24: Maintenance

    Every 2 year (Replace if necessary) Note: * Service more frequently when operating in dusty areas. ** Service by KIPOR authorized service center. 4.2 Engine oil ■ Checking for the oil level Stop the engine and check the oil level, be sure to put the engine on a flat and level surface when checking.

  • Page 25: Checking The Low Oil Alarm

    3. If the oil level is low, add to the edge of the oil filler port. ■ Replace the engine oil 1. Remove the oil dipstick and oil drain bolt, drain out dirty oil. 2. Reinstall the oil drain bolt tightly. 3.

  • Page 26: Air Cleaner

    2. Stop engine, disconnect oil alarm connector, check the connector conduction, no conduct is normal. 3. Drain out the oil inside engine and check the conduction, conduct is normal. 4.4 Air cleaner Inspection/Cleaning: 1) Loosen the cover screw and remove the maintenance cover. 2) Disengage the locking tab by pushing it, and remove the air cleaner cover.

  • Page 27: Spark Plug

    Caution ■ A dirty air cleaner will restrict air flow to the carburetor, reducing engine performance. If the engine is operated in dusty areas, clean the air cleaner more often than specified in the Maintenance Schedule. ■ Never run the engine with no element or a damaged element. Engine damage will result. 4.5 Spark plug Inspection/Cleaning: 1) Remove the spark plug cap and remove the spark plug.

  • Page 28: Valve Clearance

    4) Measure the plug gap with a wire-type feeler gauge. Adjust by bending the side electrode if the measure is not accord with the asked valve. Spark plug clearance .024-.028 in. (0.6~0.7mm) Standard spark plug 0.6-0.7 5). Install the plug finger tight to seat the washer, and then tighten with a plug wrench. Torque valve is 8.-~9.6 ft lbs, 11~13 N.m 4.6 Valve clearance Caution...
  • Page 29 2) Remove the four tighten bolts and disassemble the cylinder cover. Don’t remove the cylinder cover with excessive force as it may deform. Replace the cylinder cover if it is deformed. 3) Remove the spark plug; screw the dial indicator in the spark plug hole. Rotate the rotor in a clockwise movement and set the piston at top dead center.
  • Page 30 4) Insert a feeler gauge between the rocker arm and the valve and measure the valve clearance. Intake .0031-.0039 in (0.08-0.10mm) Valve clearance Exhaust .0039-.0059 in (0.10-0.15) mm 5) If adjustment is necessary, proceed as follows. a. Loosen the adjusting screw lock nut and adjust the valve clearance by turning the adjusting screw in or out.
  • Page 31 6) Clean the liquid gasket of the cylinder block and cylinder head cover. Apply liquid gasket (Three Bond 1207B or equivalent) to the cylinder block installation surface as shown. 7) Install all parts in the reverse order of removal. 4.7 Fuel tank/Fuel filter Caution ■...

  • Page 32: Fuel Pump And Hoses

    4.8 Fuel pump and hoses Caution ■ Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. Keep heat, sparks, and flame away. Wipe up spills immediately. 1) Drain the fuel from the tank and carburetor, and then remove the following parts. ―Rear cover ―Front cover and control panel ―Right/Left side cover...

  • Page 33: Spark Arrestor

    4.9 Spark arrestor Caution ■ Make sure the muffler has cooled completely before attempting any maintenance on this part. (1) Remove the rear cover (2) Disassemble the arrestor from muffler (3) Remove the carbon from the spark arrestor steel mesh with a stiff wire brush. Check for damage and replace it if necessary.

  • Page 34: Muffler

    5. Muffler Caution ■ Muffler removal/installation must be performed with the engine cold. ● Disassembly/Reassembly...

  • Page 35: Air Filter/Carburetor

    6. Air filter/Carburetor Caution ■ Loosen the drain oil bolt and drain out fuel before disassembly. ■ Keep heat, flame and sparks away. 6.1 Air filter removal and installation 6.2 Carburetor removal and installation...

  • Page 36: Stepping Motor Removal And Installation

    6.3 Stepping motor removal and installtion...

  • Page 37: Carburetor Exploded Drawing

    6.4 Carburetor exploded drawing Note: With the exception of changing the main jet for altitude compensation, no adjustments to this carburetor are permitted under EPA and CARB guidelines. No repair parts will be furnished. 阻风门杆 Choke valve Fork 拨叉 拨叉弹簧 Fork spring 阻风门片...

  • Page 38: Inspection

    6.5 Inspection ● Float height Place the carburetor as the picture shows, measure the float height between float and carburetor block. Height 0.0047 in (12mm) Replace the carburetor if the float height is not the right size. ● Stepping motor Measure the resistance of stepping motor lead-out wire.

  • Page 39: Control Panel

    7. Control panel 7.1 Removal/Installation...

  • Page 40: Inspection

    7.2 Inspection a. Control panel ● AC receptacle Check the electrode contact disk inside receptacle; if it is burnt or discolored, replace for it. ● DC receptacle After checking the fuse, connect both terminals of the receptacle with a jumper wire to short. There must be continuity between the lead wire terminals with the circuit protector ON.
  • Page 41 ● Engine switch Check the continuity of connector, there should be continuity when the micro switch is depressed. ● Rectifier Measure the on or off (positive pressure fall) of rectifier with control potentiometer , the measurement should accord with the standard as shown in the chart. Positive Negative...

  • Page 42: Housing/Fuel Tank

    8. Housing / Fuel tank 8.1 Housing disassembly and reassembly ● Left housing case...

  • Page 43: Fuel Tank Assembly

    8.2 Fuel tank assembly Caution ■ Gasoline is highly flammable and explosive. You can be burned or seriously injured when handing fuel. Keep heat, sparks, and flame away. Wipe up spills immediately. Loosen the drain screw to drain the carburetor thoroughly before removal.

  • Page 44: Recoil Starter/Air Conduct Cover/Igntion Coil/Air Conduct Plate

    9. Recoil starter/ Air conduct cover/ Ignition coil/ Air conduct plate 9.1 Disassembly/Reassembly...

  • Page 45: Air Conduct Plate

    9.2 Air conduct plate Disassembly/ Reassembly...

  • Page 46: Recoil Starter

    9.3 Disassembly and reassembly of recoil starter (1) Set the spring into the starter reel, and hang the spring outer hook inside the reel groove.
  • Page 47 (2) Smear lubrication grease on the starter outer shell claw, install the starter reel. Revolve the reel anticlockwise to hang the spring inner hook on the starter outer shell claw. (3) Make a “8” knot at one end of the rope, pass the other end through the reel hole. Wind the reel anticlockwise 6 turns to fix the reel.
  • Page 48 (4) Pull rope through from starter outer shell hole completely; pass it through the handle and make a figure eight knot, then turn off handle cover. Loosen the reel to release tension on the spring taking care not to allow the reel to pop out. (5) Install the revolving axis, revolving axis parts and friction spring, fix it with bolts.

  • Page 49: Ignition Coil

    9.4 Ignition Coil ● Attach the two leads of tester to the primary coil plug of ignition coil, and measure the primary resistance of the ignition coil. Primary resistance 0.8—1.3Ω ● Attach one lead of the tester to each terminal of primary coil plugs of ignition coil and the other lead to the spark plug cap，then measure the secondary resistance of the ignition coil.

  • Page 50: Alternator/Trigger

    10. Alternator/Trigger 10.1 Alternator Disassembly/Reassembly 10.2 Inspection (1) Ignition winding Measure the resistance between the green terminal and yellow/green terminal. Resistance 0.50-0.70Ω (2) Outer charging winding Measure the resistance between the two blue terminals. Resistance 0.12-0.15Ω (3) Sub winding Measure the resistance between the two sub winding terminals. Resistance White-white 0.25~0.35Ω...

  • Page 51: Trigger Adjustment

    (5) Trigger Attach the two test leads to the trigger and measure the resistance. Trigger resistance 80-130 Ω 10.3 Trigger adjustment Adjust the clearance between trigger and the projection of the rotor. Trigger clearance 0.0197-0.0275 in (0.50-0.75 mm) Insert a feeler gauge between the trigger and the projection of the rotor; loosen the trigger fixed plate bolt to adjust the clearance slightly.

  • Page 52: Cylinder Cover/Rocker Arm

    11. Cylinder cover/ Rocker arm 11.1 Disassembly/ Reassembly...

  • Page 53: Inspection

    11.2 Inspection ● Rocker arm outer diameter Standard in (mm) Service limit in (mm) 0.1570-0.1573 (3.988-3.996) 0.1555 (3.950) ● Rocker arm inner diameter of inlet/exhaust valve Standard in (mm) Service limit in (mm) 0.1575-0.1579 (4.000-4.012) 0.2598 (4.050) ● Inner diameter of rocker arm bearing Standard in (mm) Service limit in (mm) 0.1575-0.1579 4.000-4.012...

  • Page 54: Crankcase Cover/Camshaft Drive Chain

    12. Crankcase cover/ Camshaft drive chain 12.1 Disassembly 12.2 Crankcase oil tray disassembly and reassembly 1. Clean any remaining gasket material from the cylinder block and crankcase oil tray.

  • Page 55: Crankshaft Installation

    2. Apply a 0.040~0.059 in (1~1.5 mm) layer of liquid gasket material [1207B or equivalent] evenly on the sealing face of the crankcase oil tray. 3. Reassemble the crankcase cover in the reverse order of disassembly. Caution Make sure to reassemble the crankcase oil tray three minutes after applying the gasket material. 12.3 Crankshaft reinstallation 1.

  • Page 56: Crankcase Cover Assembly

    12.4 Crankcase cover assembly 1. Remove any remaining gasket material on the cylinder block and crankcase cover. 2. Apply a 0.040~0.059 in (1~1.5 mm) layer of liquid gasket material [1207B or equivalent] evenly on the cylinder block sealing face. 3. Reassemble the crankcase cover in the reverse order of disassembly. Caution Install the crankcase cover on the cylinder block 3 minutes after applying the gasket material.
  • Page 57 ● Cam height Standard in (mm) Service limit in (mm) 1.101-1.103 (27.97-28.03) 1.062 (26.97) ● Cam inner diameter Standard in (mm) Service limit in (mm) 0.1976-0.1988 (5.02-5.05) 0.2008 (5.10) ● Camshaft outer diameter, tappet shaft outer diameter Standard in (mm) Service limit in (mm) 0.1963-0.1967 (4.988-4.996) 0.1949 (4.950)
  • Page 58 ●Valve tappet inner diameter Standard in (mm) Service limit in (mm) 0.1968-0.1975 (5.000~5.018) 0.1988 (5.050)

  • Page 59: Disassembly/Reassembly

    13. Crankshaft/ Piston 13.1 Disassembly/Reassembly...

  • Page 60: Piston

    13.2 Piston Assembly of piston ring Caution ● Set the manufacture label up. ● Pay careful attention not to mix the location of the 1 ring and 2 ring. ● Check the piston ring for flexibility after installation. ● Stagger each piston ring opening 120°apart.

  • Page 61: Inspection

    ● There may be two different kinds of piston rings for the same model generator. They can be distinguished by different manufacture labels. Don’t intermix piston rings of different manufacture on the piston. 13.3 Inspection ● Free length of valve spring Standard in (mm) Service limit in (mm) 0.925 (23.5)
  • Page 62 ● Valve stem outer diameter Standard in (mm) Service limit in (mm) Intake valve 0.156-0.157 (3.965-3.980) 0.1535 (3.900) Exhaust valve 0.1557-0.1562 (3.955-3.970) 0.1535 (3.900) ● Valve guide pipe inner diameter Standard in (mm) Service limit in (mm) Intake/Exhaust valve 0.1575-0.1579 (4.000-4.012) 0.2598 (4.060) ●...
  • Page 63 ● Cylinder inner diameter Standard in (mm) Service limit in (mm) 1.712-1.714 (43.500-43.520) 1.716 (43.595) ● Piston skirt outer diameter Standard in (mm) Service limit in (mm) 1.711-1.712 (43.460-43.480) 1.707 (43.350) ● Clearance between piston and cylinder Standard in (mm) Service limit in (mm) 0.0008-0.0024 (0.02-0.06) .0047 (0.120)
  • Page 64 ● Piston skirt outer diameter Standard(mm) Service limit(mm) 57.960-57.980 57.850 ● Clearance between piston and cylinder Standard in (mm) Service limit in (mm) 0.0078-0.0165 0.020-0.042) 0.0047 (0.120) ● Side clearance of piston ring Standard in (mm) Service limit in mm) 0.0008-0.0024 (0.02-0.06) 0.0059 (0.15) ●...
  • Page 65 ● Piston ring height Standard in (mm) Service limit in (mm) The 1 ring 0.0030-0.031 (0.77-0.79) 0.028 (0.70) The 2 ring 0.038-0.039 (0.97-0.99) 0.0354 (0.90) ● Piston pin outer diameter Standard in (mm) Service limit in (mm) 0.3934-0.3937 (9.994-10.000) 0.3920 9.950 ●...
  • Page 66 ● Clearance between piston pin and piston pin hole Standard in (mm) Service limit in (mm) 0.00008-0.00055 (0.002-0.014) 0.00314 (0.080) ● Connecting rod small end inner diameter Standard in (mm) Service limit in (mm) 0.3942-0.3946 (10.012-10.024) 0.3965 (10.070) ● Connecting rod big end inner diameter Standard in (mm) Service limit in (mm) 0.5911-0.5915 (15.015-15.025)
  • Page 67 ● Crankshaft neck outer diameter Standard in (mm) Service limit in (mm) 0.5896-0.5899 (14.975-14.985) 0.5866 (14.900) ● Connecting rod big end side clearance Standard in (mm) Service limit in (mm) .0039-.0236 (0.1-0. 6) 0.0315 (0.8)
  • Page 68 ● Oil film clearance of connection rod big end (1) Wipe all oil from the surface of the crankshaft neck. (2) Set the plastic wire feeler at the crankshaft neck and install the connecting rod. Tighten the bolt to the prescribed torque being careful not to rotate the crankshaft.
  • Page 69 ●Camshaft bearing inner diameter, tappet shaft bearing inner diameter (cylinder block) Standard in mm） Service limit in (mm) 0.1976~0.1988 (5.02~5.05) 0.2008 (5.10) ●Camshaft bearing inner diameter, tappet shaft bearing inner diameter (gear case cover) Standard in mm） Service limit in (mm) 0.1976~0.1988 (5.02~5.05) 0.2008 (5.10)
  • Page 70 ● Bearing vibration Clean the bearing and dry it. check the clearance between crankshaft journal and connecting rod big end by rotating the bearing by hand. Replace the bearing if there is abnormal noise or vibration.

  • Page 71: Appendix A- Capacitor

    Appendix A- Capacitor Beginning with models built in December 2007 and ending in July, 2008, a capacitor was added to reduce electro-mechanical interference and eliminate problems with some digital clocks not displaying the time properly. This was an interim solution and all later models had an inverter module modification to eliminate the capacitor.
  • Page 72 Terminals Do not touch the exposed terminals nor attempt to take any measurements before discharging the capacitor. Use the capacitance checking mode of a multimeter. Replace the capacitor if any reading is outside the standard value of 10uF±5%.

  • Page 73: Appendix B- Carb Certified Units

    Appendix B- CARB Certified Units The fuel tank, fuel cap, indicator, and hoses are specially designed and constructed to prevent fuel vapors from permeating and be released into the atmosphere. The emission control system has the following components: 油管Ⅲ Fuel Hose Fuel Tank Certification No.

  • Page 74: Appendix C- Parallel Operation

    2011 is not permitted. There are two approved Kipor parallel kits. One has a maximum capacity of 30 amps and has a single 30 amp receptacle. The other has a capacity of 50 amps and has one single 20 amp and one single 30 amp receptacle.

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