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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 North America. 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．SPECIFICATIONS AND DIAGRAMS
1.1 General Specifications
Dimensions and weights
Model
Overall length- in. (mm)
Overall width- in. (mm)
Overall height- in. (mm)
Dry weight- lbs. (Kg)
Engine
Model
Type
Displacement- cu.in. (cc)
Bore x stroke- in. (mm)
Maximum horsepower(KVA)
Compression ratio
Cooling system
Ignition system
Ignition timing
Spark plug
Carburetor
Air cleaner
Governor
Lubrication system
Oil capacity- qt. (L)
Starting system
Stopping system
Fuel
Generator
Model
Generator type
Generator structure
Excitation
Voltage regulation system
Phase
Rotating direction
Frequency regulation
IG6000
31.6 (802)
19.5 (498)
24.6 (624)
209 (95)
KG390GETi
4-stroke,OHV, single cylinder
23.7 (389)
3.46 x 2.51 (88×64)
7.7/3600
8.5:1
Forced air
Transistorized controlled ignition
28°B.T.D.C
F7RTC
Horizontal float type
Dry replaceable element
Inverter module control
Forced splash
1.2 (1.1)
Electric starter
Electric ground
Automotive unleaded gasoline 87 octane
KD50
Multi pole rotation type
Self-ventilation drip-proof type
Self-excitation (Magnet type)
Pulse Width Modulation
Three phase
Clockwise (Viewed from the generator)
AC-DC-AC conversion (Inverter type)
1
IG6000H
48.6 (1235)
25.6 (650)
30.3 (770)
223 (103)
1.2 Generator Specifications
Model
Maximum output（AC）
Rated output (AC)
Rated frequency (HZ)
Rated voltage（AC）
Maximum current (amp)
Rated current（amp）★
Rated voltage（DC）
Rated current（DC）
Power factor
Voltage variation rate
Momentary
Average
Average time
Voltage stability
Frequency variation rate
Momentary
Average
Average time
Frequency stability
Insulation resistance
AC circuit protector- Amps 120/240 VAC
DC circuit protector
Fuel tank capacity- gal (L)
Operating hours at rated load
Noise level dB @23’ (7 m) no load-full load
IG6000
6.0 KVA
5.5 KVA
60
120/240
25/50
23.9/45.8
12V
12A
1.0
Max.10%
Max.1.5%
Max. 3 seconds
±1%
Max. .5%
Max. .5%
Max. .05 second
±0.1%
Min. 10MΩ
51.7/25.8
15A
5.9 (22)
6
63~70
2
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
3
1.4 Wiring Diagram
4
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.
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.
5
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.
6
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 manufactur er’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.
7
2.6 Alternator Maintenance Standards
Standard（
Ω）
Part Item Type
120V/240V
Ignition winding l Resistance
Orange－
Yellow/Green
Gray－orange
External charging winding
Built-in charging winding
Resistance Blue－blue
Resistance Purple－Purple
0.22~0.24
0.15~0.17
0.03~0.04
0.12~0.16
Sub winding Resistance
White－white
(green－green)
Main winding Resistance
Black－black
(red－red)
0.08~0.12
0.45~0.60 0.09~0.10 0. 9~1.1
2.7
Fastening Torques
Service limit
Item Specification
Tightening torque
Ft lb.
14.8~16.3
N.m
20~22 Connecting rod bolt
Cylinder cover bolt
Spark plug
Crankcase side cover bolt
Rotor nut
M8
M14×1.25×19
M8×30
18.4~22.2
14.8~17.0
M18×1.5 88.5~95.9
Rocker arm shaft bolt
Adjusting nut of rocker arm shaft
M8×16
M6×0.75
14.8~17.0
7.8~8.8
M5 bolt、nut 4.4~5.9
Standard torque
M6 bolt、nut
M8 bolt、nut
5.9~7.4
14.8~17.0
M10 bolt、nut
40.6~44.3
Note: Use standard torque values for fasteners that are not listed in this table.
25~30
20~23
120~130
20~23
10~12
6~8
8~10
20~23
55~60
8
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
Fuel hose clogged
Fuel switch won’t operate
Carburetor defective
Ignition coil defective
Spark plug defective
Defective timing relay
Trigger defective or improper air gap
Spark plug cap disconnected
Oil level alarm defective
Ignition coil defective
Valve clearance misadjusted
Clean
Clean
Replace
Clean and/or replace
Inspect and replace
Inspect and replace
Inspect and replace
Inspect and replace
Install securely
Inspect and replace
Inspect and replace
Adjust valves
Engine speed
does not stabilize
Carburetor faulty
Throttle control motor (stepping motor) defective
Inverter unit defective
Clean and/or replace
Inspect and replace
Inspect and replace
Valve clearance misadjusted Adjust valves
2.8.2
Hard starting or no start
Check the fuel level in the tank
↓Sufficient fuel
→no fuel Add fuel and restart the engine
Check fuel switch is in ON position
↓on
→off
Turn on it and restart the engine
Check fuel system for blockage Loosen the drain screw and check whether fuel reaches bowl and whether the fuel level is normal
↓normal
Remove and check spark plug and check if electrode is wet or dry
→ abnorma l
→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
9
Attach the spark plug on plug cap, ground the electrode on the cylinder head.; start the engine and check the spark conditions
↓normal
Install a compression gauge in the spark plug hole and restart the engine and check the cylinder compression
→no spark or weak spark
Perform the ignition system troubleshooting
1. Check valve clearance;
2. check cylinder head gasket for leakage
→low cylinder
3. Check combustion chamber for excess carbon buildup compression 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
↓no spark
Perform the spark test again using a new spark plug
↓no spark
Check ignition module
↓normal
Check resistance of ignition coil
↓normal
Check trigger air gap and trigger resistance
↓normal
Check the ignition coil resistance and high voltage cable and insulation cap
↓
Check or replace wiring harness
→normal spark
→normal spark
Replace the spark plug
Replace Ignitor
→abnormal Replace the ignition module
→abnormal Replace the coil
→abnormal
Adjust the air gap and/or replace the trigger
→abnormal
Check the ignition coil
10
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
↓conductive
Connect the alarm wire, loosen ignition module receptacle and check if the orange wire is connected with the ground
↓conductive
→not conductive
→not conductive
Replace ignition module
2.8.5 Engine speed does not increase or is unstable
Replace the oil level alarm switch
Repair wiring harness
Check choke for proper operation
↓ OK
Check the air cleaner
↓not clogged
Check the valve clearance
↓normal
→abnormal Adjust/repair choke mechanism
→clogged Clean or replace air cleaner
→abnormal Adjust the valve clearance
Remove the spark plug and check the electrodes for carbon and spark plug gap
↓normal
Check for blockage of the main jet
→abnormal
Clean the spark plug and adjust the spark plug gap or replace new spark plug
↓not clogged
Check the air intake gasket and the sealing of heat-insulation block of carburetor
↓normal
Perform the cylinder compression check
→clogged
Disassemble and clean or replace carburetor
Tighten the nuts securely, replace the
→abnormal gasket or heat-insulation block
↓normal
Perform the throttle control system troubleshooting
→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.
11
2.8.6 Engine stops after starting
Check the engine oil level and check if oil level alarm activates when rotation stops
↓sufficient oil
Check the fuel in fuel tank
↓sufficient fuel
Check for operation of fuel switch and blockage in fuel filter
↓not clogged
Check for blockage of fuel hoses
↓not clogged
Check for carburetor fuel delivery
↓normal fuel flow
Check the intake gasket and the sealing of carburetor heat-insulation block
↓normal
→oil level alarm
Add oil and restart the engine
→no fuel
Add fuel and restart the engine
→clogged
Clean the fuel switch and filter
→clogged Clean or replace the hoses
→not fueling
Disassemble and clean
→abnormal
Tighten the nuts securely, replace the gasket or heat-insulation block
Measure the cylinder compression
↓normal
Check the trigger air gap
↓normal
→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.
→abnormal Readjust the clearance
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
↓normal
→abnormal Replace the stepping motor
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
12
↓normal
Check the stepping motor
↓normal
Check the smart throttle switch
↓normal
Check “Smart” switch wire
↓normal
Replace the inverter unit
2.8.8 Low AC output
Is the overload indicator light ON?
↓off
Is the engine speed normal?
Smart switch operation:
On: 2500±100rpm
Off: 3600±100rpm
↓normal
Check the AC receptacle
↓normal
Check the AC output 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.
↓normal (255 volts)
Replace inverter unit
2.8.9 No AC output
Is the engine speed normal?
→abnormal Replace the stepping motor
→abnormal Replace the smart throttle switch
→abnormal Repair or replace the wire harness
→on
→abnormal output”
Disconnect the load, and restart the engine.
Perform the throttle control system troubleshooting
→abnormal Replace the receptacle
→abnormal Replace the connector
→abnormal
1. Check the wiring of the stator leads in the harness. Repair or replace the harness.
2. Replace the alternator.
↓normal
Check AC receptacles
↓normal
Check the rectifier
↓normal
Measure the resistance between two blue wire on the rectifier
Resistance:0.03~0.04
Ω
↓normal
Rotor losses excitation, replace the rotor abnormal
Perform the throttle control system troubleshooting
→abnormal Repair wiring or replace receptacles2.7.9
→abnormal Replace the rectifier
→abnormal
Check and repair the wire harness or replace the stator
13
2.8.10 Electric Starter
Check the battery voltage
↓normal
Check ignition switch
↓normal
Check the ignition relay
↓normal
Check the starting motor
↓normal
→abnormal Charge or replace the battery
→abnormal Replace the ignition switch
→abnormal Replace ignition relay
→abnormal Replace the starting motor
Check and repair or replace main wire
Check charging regulator
↓normal
Check ignition switch
↓normal harness
2.8.11 The battery will not charge or maintain a charge
→abnormal Replace ignition switch
→abnormal Replace the charging regulator
Measure resistance of charging coil winding
Resistance: 0.1
2~0.16Ω:
↓
→abnormal
Check and repair electric wire harness or replace stator.
Check and repair or replace wire harness
14
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
Each use Each month or every 10 hours
Project
Engine Oil
Air cleaner
Spark plug
Spark Arrestor
Check
Replace
Check
Replace
Clean-Adjust
●
●
Clean
●
Every 3 months or every
50 hours
●*
Every 6 months or every 100 hours
●
●
●
Valve clearance Check-Adjust
Fuel tank and filter Clean
Fuel line Check Every 2 years and replace if necessary
Every year or every
300 hours
●**
●**
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.
15
（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.
16
3.3 Low Oil alarm inspection
Disconnect the orange oil alarm wire when the engine stops and ground the terminal specified in the diagram and confirm that the alarm light is on and the engine stops or won’t restart.
Outlet terminal of ignition module
Outlet terminal of oil alarm Ground through engine cover
3.4
Air Cleaner
（1）Open the door of cabinet.
（2）Remove the air cleaner cover and remove the filter element.
（3）Check the element for excessive dirt or damage. Replace as necessary
Caution:
●Excess oil will restrict air flow through the foam filter core and may smoke at the engine start.
Filter element
Cover of ail cleaner
Clean Twist to dry Dip into oil Squeeze out the excess oil
17
（4）Install the air cleaner element in the air cleaner case.
Caution
Do not operation the engine without an air filter element or with a damaged air filter. Rapid engine wear will result
3.5 Spark plug inspection and adjustment:
（1）Remove the spark plug cap and remove the spark plug with plug sleeve
（2）Remove carbon on the electrodes of spark plug with a wiey brush and check sealing washer for damage.
（3）Check the resistance value of spark plug and replace if the resistance value is not within the stated value.
Resistance value of spark plug
3~9KΩ
（4）Measure the plug gap with a wire-type feeler gauge. If the gap is not compatible with the standard, adjust by bending the side electrode.
Spark plug gap .028-.034 in. (0.7~0.8 mm)
Standard spark plug F7RTC
0.7-0.8
（5）Install the plug and tighten securely after adjustment.
18
3.6 Valve clearance adjustment
Caution
● Valve clearance inspection and adjustment must be performed on a cold engine.
（1）Remove spark plug, valve cover bolt, valve cover and valve cover gasket.
Spark plug Valve cover gasket
Valve cover
（2）Insert a feeler gauge in the spark plug installation hole; Rotate the engine so the piston is at top dead center and both intake and exhaust valves are closed. r
（3）Insert a feeler gauge between the rocker arm and the valve and measure the valve clearance.
Valve clearance intake：.0039 ± .0001 in. (0.10 ± 0.02 mm)
exhaust：.0059 ± .0001 (0.15 ± 0.02 mm)
19
（4）If adjustment is necessary, proceed as follows: a. lock the rocker lever adjustment screw and loosen the nut. b. move the rocker lever adjustment screw until the correct clearance is acheived. c. tighten the nut on the rocker arm adjustment screw. d. recheck the clearance.
3.7 Fuel switch and fuel filter cleaning
Fuel tank
Sealing gasket
Filter core or element
Fuel switch
（1）Drain the fuel from the tank then remove the fuel tank.
（2）Loosen the connection nut between fuel switch and tank and remove the filter core.
（3）Open the fuel switch to start cleaning and dry it with compressed air.
（4）Remove any clogged foreign material from the fuel filter core and check the fuel filter for damage.
（5）Install the sealing gasket, filter core, and fasten the connection nut between fuel switch and oil tank.
20
4．AIR CLEANER AND MUFFLER
4.1 Air cleaner
● Disassemble and reassemble
Bottom case of air filter
Sealed gasket
Filter fixed price
Filter element
Carburetor gasket Air filter cover
Install:
Make sure that gaskets have no damage or deformation. Check sealing surfaces on all four sides
4.2 Muffler
● Assembly
Muffler syphon
Fireproofing cap
Assembly:
Clean the carbon using the brush before installing
Cover of muffler
Exhaust pipe gasket
Muffler gasket
Muffler
Assembly:
Knock it to remove carbon inside by using rubber hammer before installing.
21
5．
Carburetor
WARNING
This carburetor is not to be rebuilt nor adjusted and no repair parts will be furnished. The only maintenance permitted other than cleaning is to replace the main jet for high altitude compensation.
5.1 Disassembly and reassembly
NOTE: loosen the drain bolt at the bottom of the bowl and drain fuel from the carburetor before removal.
Carburetor gasket A
28
Reassembly:
Check if there is any damage in the gasket before assembly
22
● Disassembly and installation of stepping motor
Stepping motor
Stepping motor base
Fork
Fork spring disassembly:
Hold tight to prevent spring from coming loose
.
Fork spring
Fuel control lever Fork
5.2 Stepping motor/ fuel shutoff solenoid
1）Measure the resistance of outlet terminals of stepping motor resistance value
1 and 3：
50~55Ω
2 and 4：
50~55Ω
Replace the stepping motor if the resistance exceeds the standard.
2）Measure the resistance of fuel shutoff valve resistance value
6~8Ω
Replace the throttle electromagnetic valve if the resistance exceeds the standard value
1
4
2
3
23
6.
Control Panel and Inverter
6.1 Disassembly and reassembly
Timing relay Control panel
Ignition control module
Module fixing plate 2
Inverter unit
Charging regulator Module fixing plate1
6.2 AC Receptacle
Check for evidence of burning or contact damage. Replace if either condition exists.
6.3 DC Receptacle
Connect both terminals of the receptacle with a jumper wire and check if the receptacle is conductive with two meter leads inserted into the panel; if not conductive, press t he “Reset” button on the receptacle panel and measure it again. If there is still no continuity, replace the DC receptacle.
6.4 Smart Throttle Switch
The switch is conductive when “ON” and not conductive when “OFF”.
6.5 Ignition Module
Remove the 10P connector from the module and connect one meter lead to the cover and the other lead to the 10P connector and measure resistance.
24
Color of wire
Blue
Orange
Circuit unit
Primary coil of the ignition coil
Oil level switch
Stipulated resistance
0.8~1.3Ω
No continuity under normal oil level
80~130Ω
Yellow Coil of trigger head
Yellow/Green ground Continuity
Green Power coil winding of module
0.37~0.41Ω
Red
Engine stop switch Continuity when “OFF” and no continuity when “ON”
Blue Orange Yellow Yellow-green Green Red
(
6.6 Ignition Switch
Check for continuity of each group of contacts with the switch in the off, on, and start positions.
6.7 Bridge Rectifier
Measure the (positive voltage drop) of each leading feet of rectifier bridge with the diode checking
) function of the meter and the result should be compatible with the following standard.
Tester
(+)
Tester (-)
1 2 3 4
1 Infinity
Infinity Infinity
2 Continuity
Infinity Infinity
3
4
Continuity
Continuity
Continuity
Infinity Infinity
Continuity
25
(1)Negative terminal (-) (2) AC terminal (~)
(3) AC terminal (~) (4)Negative terminal (+)
6.8 Charging Regulator
Loosen the positive battery cable when starting the engine and connect a DC current meter between the positive cable and positive terminal. The indicated current cannot exceed 1.5A. If there is no current present, replace the regulator
DC charging voltage
DC charging current
13~14V
＜1.5A
AC Input (blue)
Shell grounding Output positive pole (red)
6.9 Timing relay
Put the ignition switch on the “OFF” position, connect a voltmeter to the white and yellow/green wires.
Place the ignition switch in the “ON” position, hold on for 7 seconds and then place in the “OFF” position.
A reading of 12V should be present for 7~12 seconds then the output should drop to 0 volts.
Yellow Green White
Red Blue
Black Black
26
6.10 Ignition Control Relay
Start the engine, turn off the smart throttle and measure the voltage between green and yellow/green wires on the connection of the control module. Replace the ignition control module if the voltage exceeds stipulated voltage.
Ignition voltage
(AC)
27~32V
Yellow Green Black
Orange Grey
Green Yellow Green
6.11 Inverter Module
Unplug the two stator input connections to the module. Start the engine and take a voltage reading at both 4P connections. Readings between pins 1-2, 2-3, 1-3 should be 255VAC ± 15V.
2 3
1
Alternator Input Terminals 4P connectors
27
7．
FRAME, HOUSING, AND FUEL TANK
7.1 Disassembly and reassembly
28
7.2 IG6000h handle assembly
29
8.
ALTERNATOR, IGNITION COIL, TRIGGER, STARTER MOTOR, FAN COVER
8.1 Component Identification
30
8.2 Ignition coil and trigger
8.2.1 Disassembly and reassembly
点火线圈
Ignition
点火线圈支架
Bracket for ignition coil coil
触发头
Trigger
8.2.2 Inspection a. Ignition coil
● using an ohmmeter, measure the primary resistance of the coil.
Primary resistance value
0.8~1.3Ω
● measure the secondary resistance of the coil.
Secondary resistance value
31
15~21KΩ
● Trigger
Measure the trigger resistance.
Trigger head resistance
80~130Ω
● Trigger Air Gap Adjustment
Adjust the clearance between the trigger head and rotor.
Trigger head clearance
.020-.029 in. (0.50~0.75 mm)
Insert the feeler gauge between the bulge on the trigger head and the rotor to measure clearance.
Loosen the two bolts on the bracket to obtain the proper. When tightening, apply equal torque to both mounting bolts to prevent “cocking” the trigger to one side. Recheck the clearance after the adjustment has been made.
32
8.3 Alternator
8.3.1 Disassembly and reassembly
8.3.2 Inspection
● Ignition coil
Flywheel nut M8x1.5
88.5~95.9 ft. lb
( lob.(120~130N.m)
Orange-Yellow/green
0.22~0.24Ω
Resistance value
Gray-Orange
0.15~0.17Ω
● External charging coil
Measure the resistance between the two blue wires
Resistance value
0.03~0.04Ω
● Built-in charging coil
Measure the resistance between the two purple wires.
Resistance value
33
0.12~0.16Ω
● Sub winding coil
Measure the resistance between two white wires (or green depending on the date of manufacture).
Resistance value
0.08~0.12Ω
●Main winding
Measure the resistance between two wires in black.
Resistance value
0.45~0.60Ω
__________________________________________________________________________________
NOTES:
34
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