KIPOR POWER PRODUCTS CO.

, LTD

GENERATOR SHOP MANUAL

KDE5000
KDE5000T

Wuxi Kipor Power Co., Ltd.

January, 2012
PREFACE

This manual covers the construction, function and servicing procedure of the Kipor KDE5000E and
KDE5000T North American model generators. This manual is principally concerned with the generator
specifications, function, troubleshooting and repair. See the owners manual for the preventive
maintenance schedule and instructions. There is a separate manual to cover overhaul, repair and
troubleshooting of the KM186FAG diesel engine.

The current versions of these generators are significantly different from the KDE6700TA and KDE6500E
formerly sold in North America. Additionally, the engine has been upgraded for 2012. Contact Kipor for the
proper service literature and parts 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.

WUXI 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.

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Table of Contents
1. Specifications and Data................................................................................................................ 4
1.1 Specifications.........................................................................................................................................................4
1.2 KDE5000E Wiring Diagram......................................................................................................................................5
1.3 KDE5000T Wiring Diagram......................................................................................................................................6
1.4 Component Identification KDE5000E......................................................................................................................7
1.5 Component Identification KDE5000T......................................................................................................................8
1.6 Control Panel- KDE5000E........................................................................................................................................9
1.7 Control Panel- KDE5000T........................................................................................................................................9
1.8 Serial Number Location........................................................................................................................................10

2. Service Information............................................................................................................ 11
2.1 The Importance of Proper Servicing......................................................................................................................11
2.2 Important Safety Precautions...............................................................................................................................11
2.3 Service Rules........................................................................................................................................................11
2.4 Electrical Precautions...........................................................................................................................................12
2.5 Generator Service Standards................................................................................................................................13
2.6 Fasteners and Torque Values.................................................................................................................................13
2.7 Troubleshooting...................................................................................................................................................15

3. Generator Testing and Repair.............................................................................................. 22

3.1 Start Switch..........................................................................................................................................................22
3.2 Voltmeter.............................................................................................................................................................23
3.3 Circuit Breaker......................................................................................................................................................23
3.4 Oil Alarm..............................................................................................................................................................24
3.5 Generator............................................................................................................................................................27

4. Electrical Components........................................................................................................ 29
4.1 Receptacle Wiring................................................................................................................................................29
4.2 AVR Adjustment...................................................................................................................................................30
4.3 Battery Charge Regulator......................................................................................................................................31
4.4 Current Transformer.............................................................................................................................................31
4.5 Rotor Checking.....................................................................................................................................................33
4.6 Stator Test Points..................................................................................................................................................34
4.7 Main Stator Winding Check..................................................................................................................................35
4.8 Secondary and Sampling Winding Check..............................................................................................................36
4.9 Charge Winding Check..........................................................................................................................................37
4.10 Carbon Brush Check...........................................................................................................................................37

5. KDE5000T Display Panel..................................................................................................... 38

5.1 Setting..................................................................................................................................................................38
5.2 Connection...........................................................................................................................................................38
5.3 Troubleshooting and Repair..................................................................................................................................38

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1. SPECIFICATIONS AND DATA
1.1 Specifications

Model
KDE5000E KDE5000T
Item
Rated frequency (Hz) 60 60
Rated power (kVA) 4.5 4.5
Rated voltage (ACV) 120/240 120/240
Rated current (ACV) 37.5/18.8 37.5/18.8
Rated speed (rpm) 3600 3600
Phase Single phase
Power factor 1.0
Excitation mode Self-excitation constant voltage (AVR)
AC Receptacles 1 120V 15A GFCI, 1 120V 30A ,1 120/240V 30A
Structure mode Open frame Enclosed
Coupling method Transmission rigid connection
Gross weight lbs. (kg) 209 (95) 376 (171)
Overall dimensions LxWxH in. 28.4 x 18.9 x 33.3 35.8 x 20.5 x 29.1
(mm) (720 x 480 x 845) (910 x 520 x 740)

Model
KDE5000E KDE5000TA
Item
Model KM186FAGE(X) KM186FAGET
Type
4-stroke, single-cylinder, air-cooled, direct injection
diesel engine
Max output (kW/rpm)
6.6
Bore x stroke in (mm)
3.4 x 2.8 (86 x72)
Displacement in (L)
0.418
Cooling system
Forced air-cooled system
Lubricating system
Pressure splashing
Lube oil capacity qt. (L)
1.5 (1.65)
Starting system Recoil/electric Electric
Fuel Diesel
Fuel tank volume gal (L) 3.9 (15) 4.2 (16)
Run time at rated load- hrs 8 8.5
Low oil alarm system included

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1-2 KDE5000E wiring diagram

5
1-3 KDE5000T wiring diagram

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1.4 Component Identification- KDE5000E

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1.5 Component Identification KDE5000T

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1.5 Control Panel- KDE5000E

1.5 Control Panel- KDE5000T

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1.9 Serial number identification and location

The generator serial number identifies your particular unit and is important when ordering parts and
accessories. A serial number bar code sticker is placed on the generator, on the shipping carton, and on the
inside cover of the owners manual. Additionally, it is engraved onto a metal serial number tag riveted to the
generator.

The serial number for the KDE5000T is located on the

chassis to the left of the battery and below the oil drain plug.

The serial number for the KDE5000E can be found on the

left side of the generator frame below the control panel.
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.

! 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 Important 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.

2.3 Service rules

Use genuine KIPOR or KIPOR-recommended parts and lubricants or their equivalents. Parts that do not
meet Kipors design specifications may damage the engine.

Use the special tools designed for the product.

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.

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 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.

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 manufacturers
operating instructions carefully before operating the tester. Be sure that the tester battery is fully charged and
the meter is functioning properly

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 2.5 Generator Service Standards

Winding Resistance standard ()

Standard value of voltage
at No load (VAC)
Main Winding 0.75-0.85 240
Secondary Winding 2.5 135
Sampling Winding 0.5 16
Charge Winding* 2.5 13/13
Rotor Winding 40-45 70
*Charge receptacle removed from North American models but windings are present

2.6 Fasteners and Torque Values

(1) KDE5000E
Inner
Item diameter
Description Torque Value
of
screw X N.M Lbf
length
Front end cover Hexagonal flange face bolt M8X25 18 13
Rotor through bolt Hexagonal flange face bolt M10X210 50 36
Tighten bolt of fore/back
end cover Hexagonal flange face bolt M6X140 10 7
Frame power Hexagonal flange face bolt M10X45 40 29
Hexagonal bolt M10 40 29
Earth wire Hexagonal flange face bolt M6X12 9 7
Electromagnet Cross slotted pan head screw M3X5
Cross slotted pan head screw M4X8
Anti-hunting bracket Hexagonal flange face bolt M8X16 20 15
Oil tank Hexagonal flange face bolt M6X25 9 7
Hexagonal bolt M6 9 7
Decorating plate Hexagonal flange face bolt M6X25 9 7
Hexagonal bolt M6 9 7
Carbon brush Hexagonal flange face bolt M5X20
Rectification block Hexagonal flange face bolt M5X20
Earth wire Hexagonal flange face bolt M5X12
Back cover Hexagonal flange face bolt M5X12
AVR Hexagonal bolt M5
Oil tank assembly Cross slotted pan head screw M5X12
Cross slotted pan head screw M5X8
Nut M6 9 7
Panel Cross slotted pan head screw M6X16 9 7
Hydraulic pressure
regulator Hexagonal flange face bolt M6X18 9 7
Battery bracket Hexagonal flange face bolt M8X16 20 15
Hexagonal bolt M8 30 22
Hexagonal flange face bolt M6X12 9 7
Nnt M6 9 7
Battery Butterfly nut M6 9 7

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(2) KDE5000TA
Inner

Item diameter
Description Torque Value
of
screw X N.m Lbf
length
British
standard3/8 16
Front end cover tooth bolt 30 22
Rotor through bolt Hexagonal flange face bolt M10X225 50 36
Tighten bolt of
front/back end
cover Hexagonal flange face bolt M6X150 10 7
Frame power Hexagonal bolt M8 18 13
Hexagonal bolt M10 50 36
Earth wire Hexagonal flange face bolt M6X8 9 7
Muffler Hexagonal bolt M8 30 22
Fixed Hexagonal flange face bolt M8X25 20 15
Hexagonal flange face bolt M6X12 9 7
Panel Cross slotted pan head screw M6X16 9 7
Nut M6 9 7
AVR Hexagonal flange face bolt M5X16
Carbon brush Hexagonal flange face bolt M5X20
Rectification Hexagonal flange face bolt M5X20
Earth wire Hexagonal flange face bolt M5X12
Back cover of
motor Hexagonal flange face bolt M5X12
Oil tank Hexagonal flange face bolt M6X20 9 7
Fixed air cleaner Nut M6 9 7
Charging regulator Hexagonal flange face bolt M8X25 20 15
Bracket Hexagonal flange face bolt M6X12 9 7
Battery bracket Hexagonal flange face bolt M8X16 20 15
Hexagonal bolt M8 20 15
Hexagonal flange face bolt M6X12 9 7
Hexagonal bolt M6 9 7
Battery Butterfly nut M6 9 7

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2.7 Troubleshooting
Note: The engine shop manual is necessary to troubleshoot, test, and repair many of the faults listed below.
2.7.1 General symptoms and possible cause
(1) Diesel engine cannot start or is difficult to start (see engine shop repair manual)
Fault:
Deteriorated diesel fuel
Fuel is not sufficient
Fuel cock is not at the START position.
Fuel delivery line from fuel tank is bent or
pipe is clogged
Fuel filter is clogged
The injection pump does not deliver fuel
Fuel injector does not deliver fuel
The governor lever of engine throttle is not
in the START position
Engine oil filter is clogged causing low oil
protection
Solenoid fuel valve is clogged or does not
work because power is off
The governor lever of engine throttle is
defective
The ignition switch fails to engage starter
Starting motor is defective
Oil alert switch wont allow ignition
The battery is discharged
Valves are improperly adjusted
Engine is seized
Remedy:
Drain the fuel, refill with fresh fuel
Add sufficient fuel
Turn it to START position
Check fuel line
Clean or replace
Remove the high pressure fuel line, check for fuel flow,
repair or replace pump
Remove the fuel injector, check nozzle- clean or replace
Switch to START
Clean or replace oil filter
Check the 12V power supply and/or replace solenoid
valve
Check and replace as necessary
Check battery, ignition switch, starting relay
Replace
Check and replace as necessary
Check battery and battery charge regulator
Check or adjust valve clearance.
Check and observe the engine rotation, disassemble the
engine to and determine cause of failure.
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(2) Engine speed is unstable, too high or too low (see engine repair manual)

Fault:
Remedy:
The fuel supply is insufficient
Adjust or disassemble and clean
Injection pump or injector is defective
Check or replace
Generator has an overload or short
Repair the fault
circuit fault
Engine governor spring is faulty
Replace the springs
Valves out of adjustment
Adjust valves

(3)The generator produces no AC power or the voltage is abnormal or fluctuating.

Fault: Remedy:
Gauge panel of 1. Circuit breaker fails to
Remove it and check for open circuit. The
generating set function
resistance reading should be 0
2. The wiring of gauge
Check for continuity in the wiring harness.
panel is loose
3. The connection of
Check or replace receptacle
receptacle is loose or
contact broken.

Alternator fault 1. The stator leads are not

Check the wiring harness
properly connected
2.The four point output
Check or replace terminal
terminal is cracked

3. Short, open, or
Check resistance values of all windings.
grounded stator windings
Replace stator if shorted, open or grounded
4 Loss of magnetism in
Check AVR
main rotor

5. Short, open, or
Check resistance values and replace rotor as
grounded rotor windings
necessary
6. Carbon brush assembly
Check resistance value at slip rings. Check
defective
brushes for wear, weak spring tension
7. Insulation resistance of
Check insulation resistance of stator and rotor.
generator is too low.
Replace stator and rotor as necessary.

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(3) AVR fault

Fault: Remedy:

1. Voltage cannot be regulated Adjust or replace AVR

2. Generator set automatically stopped after Check output voltage, adjust or replace AVR
loading, current setting incorrect
3. Electric component failed Replace AVR

4. Sampling signal but no exciting output
5. The voltage cannot be established because of
insufficient residual voltage in the stator
6. Power loss is increased because of higher
voltage output of the secondary winding
7. The voltage deviation of zero load and full load is
too large.
Check exciting output voltage of AVR. Adjust and or replace.
Check that the voltage of main winding is 6 V or more with
AVR disconnected.
Check that the voltage of secondary winding should not be
greater than 140 VAC
- Check AVR and stator.
- This may be caused by operating the generator in too high

of an ambient temperature.

8. Overload shutdown caused by high power Check inductive loads for low power factor and adjust size
factor loading of load to rated power*

Divide the appliance current draw by its power factor to determine the effect on the generator. A device
pulling 40 amps with a power factor of .85 places a 47 amp draw on the generator (40/.85). In this example, the
generator would experience an overload shutdown.

(4) Display panel fault

Fault: Remedy:

1. No display on screen.
Check 12V power supply of the generator and check wiring. If
2. Displays wrong code. OK, replace the display unit

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 2.8.2 Troubleshooting flow charts
(1) Hard starting

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(2) No AC voltage

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(3) No Voltage Regulation

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(4) Generator shutdown

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3. GENERATOR REPAIR
3.1 Start switch
Check: Circuit should be closed when switched on. Circuit should be open when switched off. In starting
position the circuit should be closed.

1 2 3 4 5 6 7

OFF --------- ---------- ---------- ----------

ON ---------- ---------

START ---------- ---------- ----------

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 3.2 Voltmeter (KGE5000E)
Check generator output with a multimeter. The reading should agree with the voltage meter. If the voltmeter has
no output or it varies with the generator output, test and replace as necessary.

3.3 Circuit Breaker

Check: Measure the resistance at two ends of air switch with a multimeter. The resistance should be infinity
when the circuit breaker is in the off position and zero when on.

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3.4 Oil alert PCB and pressure switch

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25
3.5 Generator
3.5.1 Check
(1) Front end cover: check for cracks
(2) Generator fan: check for missing or chipped blades
(3) Rotor: make sure it is clean and free of engine contaminants like grease and oil.
Normal measured resistance should comply with section 2.5. The copper windings should be clean and
bright with no trace of corrosion. Black or cracked windings indicate a short necessitating replacement.
(4) Clip ring: It should be smooth without any defect or distortion. The semicircle of the center boss
should be clear. In case of distortion replace the clip ring
(5) Through bolt: tightening torque is 37-41 Lbf (50-55 N.m). This is essential to ensure the generator
wont be damaged by scrubbing of the rotor and stator.
(6) Stator: Check the external enamel covered wire for defects after disassembly and reassembly. Do not
contact the copper windings with ground or pieces of sharp metal to prevent scuffing.
Stator checks: Check the resistance of the main winding, secondary winding, sampling winding and
battery charge winding. The stator must be changed if any resistance reading is outside the parameters.
However, insure that there is continuity in the harness before proceeding with a stator change.

(a) Main winding: Check resistance on the four position terminal board. You should have 0.75 to 0.85
between L1 and L2 and R1 and R2. Check the zero on your meter before checking these values.

(b) Secondary or sub winding: Locate the 4 pin connector at the top of the stator. Check the resistance
between the two blue green wires. The nominal value is 2.5 .
(c) Sampling winding: On the same 4 pin connector, check the resistance between the two yellow wires.
The value is 0.5 . Check the zero on your meter before checking these values.

(d) Charge winding: Find the 4 pin connector at the top of the stator. There are only two pins. The
resistance value should be 2.5 .
(7) Carbon brush: There should be no open circuit between lug and pole of the carbon brush and no short
circuit between the two poles. Check the brushes for wear. If the brush wear is uneven or the length is less
than 0.12 in. (3mm) replace.

(8) Rear end cover: check for cracking.

3.5.2 Disassembly

(1) Open the rear end cover for open frame generator. Remove the cabinet, cooling plate, left and right
side plates, and muffler for TA model.
(2) Remove the alternator assembly with the harness. With the KDE5000T, you must remove the air
induction hood to get to the harness.
(3) Remove 4 - M6 x 175M bolts from the rear end cover.
(4) Remove the stator.
(5) Secure the rotor to prevent it from dropping and remove the 10mm flange bolt.
(6) Remove the rotor with a puller.

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3.5.3 Rotor Installation
Caution: Remove any dust and oil pollution from the crankshaft and rotor. Check the resistance of the new part
before installation.
1) Insert the semicircle clip ring into key groove.
2) Install the rotor on the crankshaft.
(3) Secure the rotor with a strap wrench and tighten the 10mm flange bolt: tightening torque: 37.5 Lbf
(50 N.m)
3.5.4 Stator Installation

(1) Before installing a new stator, check the resistance values of the new part.
(2) Adjust the spacing between the stator and rotor.

Insert a feeler gauge between the stator winding and the projection of the rotor.
Rotate the rotor one complete revolution.
Secure the flange bolt connecting stator and front end cover. The locking torque is 7.5 Lbf (10-13
N.m)

The correct spacing is 0.020+/-0.004 in (0.25 +/- 0.1 mm)

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4. Electrical Component Illustrations
4.1 Receptacle wiring

29
4.2 AVR Adjustment

30
4-3 Battery Charge Regulator

4.4 Current Transformer

31
 4-5 Rotor Checking

Note: use the values for the KDA6700TA for both the KDE5000E and KDE5000TA

33
32
 4-6 Stator Test Points

CHARGE WINDING PLUG SECONDARY AND SENSING WINDING PLUG

CARBON BRUSH

L1
L2
R1
R2

\
4-7 Main Stator Winding Check

Note: use the values for the KDA6700TA for both the KDE5000E and KDE5000TA

35
4.8 Stator Secondary Winding and Sampling Winding Check

Note: use the values for the KDA6700TA for both the KDE5000E and
KDE5000TA
The color of the secondary winding may be blue instead of green

36
4.9 Charge Winding Check

Note: use the values for the KDA6700TA for both the KDE5000E and KDE5000TA

4-10 Carbon brush check

37
5. KDE5000T DISPLAY PANEL
5.1 Setting
The digital display panel is preset at the factory.

5.2 Connection

1. Unit voltage input 1

2. Unit voltage input 2
3. Current transformer secondary input 1
4. External relay input 1
5. Current transformer secondary input 2
6. External relay input 2
7. Battery negative pole
8. Battery positive pole

5.2 Troubleshooting and Repair

There is no field level repair on the display unit. After checking the wiring harness for continuity, the unit must
be replaced.

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