Kipor KDE5000E 5000TA Service Manual[1]

K IPOR POWER PRODUCTS CO., LTD GENERATOR SHOP MANUAL

KDE5000E KDE5000TA

The The Coast Coast Dist Distrribu ibution ion Syst Syste em, Inc. Inc. J anu anuary ary, 2007

PREFACE This This manu anual cov covers ers the con constr structio ction n, fun functio ction n and and ser servicin icing g proced ocedu ure of the Kipor Kipor KDE5000E and KDE5000TA Coast Distribution model generators. This manual is principally concerned with the generator specifications, function, troubleshooting and repair. See the owner’s manual for the preventive maintenance schedule and instructions. Ther There e is a sep separat arate e manu anual to cov cover over overh haul, aul, repai epairr and and troub oublesh leshoo ootting ing of the KM18 KM186FA diesel engine. engine. 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. KIP KI P OR P OWER OWE R CO., LTD, LTD, reserves the the right right to make changes changes without without incurring incurring any obligation whatever. No part of this publication may be reproduced without written permission.

2

TABL AB L E OF CONTENTS CONTENTS 1. Specifications and Data 1.1 Specifications Specifications ............................................................... ................................................................................................ .....................................4 ....4 1.2 KDE500 KDE 5000E 0E wiring wiring diagram... diagram..................................... ................................................................... ...........................................5 ..........5 1.3 KDE KDE5000TA 5000TA wiring diagram ............ ................... .............. ............... ............... .............. .............. ............... ............... ............. ......6 6 1.4 Compon omponent ent Iden Identtificationification- KDE500 KDE 5000E 0E ............................... ..............................................................7 ...............................7 1.5 Component omponent IdentificationIdentification- KDE KDE5000TA 5000TA .............. ...................... ............... .............. ............... ............... .............. .......8 8 1.6 Control ontrol P anelanel- KDE500 KDE5000E 0E ............................................................... ..............................................................................9 ...............9 1.7 Control Control Pane P anell- KDE K DE500 5000TA 0TA .................................. ................................................................... ...........................................9 ..........9 1.8 KDE50 KDE 5000T 00TA A Digital Digital Display Pane P anell ............................................................... ...................................................................10 ....10 1.9 Serial number number and bar code location ............... ...................... .............. ............... ............... .............. ............... ...........11 ...11 2. Service ervice Inform Information ation ............................... ................................................................ ................................................................. .....................................12 .....12 2.1 The import importance ance of proper proper servicing .............. ..................... ............... ............... .............. ............... ............... .............. .......12 12 2.2 Important safety precautions.............................................................................12 2.3 Serv Service ice rules ............................................................... ................................................................................................ .....................................12 ....12 2.4 Elect E lectrical rical precaut precautions ions ................................ ................................................................. ......................................................13 .....................13 2.5 Generator Service Standards............................................................................14 2.6 F asteners asteners and torque torque values ............... ...................... .............. ............... ............... .............. .............. ............... ............... ........15 .15 2.7 Digital panel protection protection values ............... ...................... .............. ............... ............... ............... ............... .............. ............. ......15 15 2.8 Troubleshoot Troubleshooting ing ................................................................ ...............................................................................................1 ...............................15 5 3. Generator Generator Repair......................................... Repair.......................................................................... .................................................................2 ................................23 3 3.1 Start swit switch ch ................................ ................................................................ ................................................................. ......................................23 .....23 3.2 Voltmet Voltmeter er ............................................................... ................................................................................................ ..........................................24 .........24 3.3 Circuit C ircuit brea breaker ker ................................ ................................................................. .................................................................2 ................................24 4 3.4 Oil alert........................................................ alert.......................................................................................... ......................................................25 ....................25 3.5 Generat Generator or ................................. .................................................................. ................................................................... ......................................28 ....28 4. Electrical lectrical Componen Componentt Illustrat Illustrations............................................................ ions................................................................................30 ....................30 4.1 Recept R eceptacle wiring wiring ................................ ................................................................. ............................................................30 ...........................30 4.2 AVR adjustm adjustment................................ ent................................................................. .................................................................3 ................................31 1 4.3 Battery Battery charge regulator regulator ............... ...................... ............... ............... .............. ............... ............... ............... ............... .............. ........32 .32 4.4 Current transformer...........................................................................................32 4.5 Rotor check checking ing ............................... ................................................................ .................................................................3 ................................34 4 4.6 Stator Stator test test points points ... .......... .............. ............... ............... .............. ............... ............... .............. ............... ............... .............. ............... ...........35 ...35 4.7 Main stator winding check.................................................................................36 4.8 Stator Stator secondary and sampling winding winding check check .............. ...................... ............... .............. ............... ...........37 ...37 4.9 Char C harge ge winding winding check ................................ ................................................................ .....................................................38 .....................38 4.10 C arbon arbon brush brush check........................................................ check........................................................................................3 ................................38 8 5. KDE KDE50 5000T 00TA A display panel panel ............................... ................................................................ ...........................................................39 ..........................39

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1. SPECIFICATIONS AND DATA 1.1 Specifications

Model

KDE5000E

KDE5000TA

Rated frequency frequency (Hz)

60

60

Rated power (kVA)

4.5

4.5

Rated voltage voltage (ACV) (AC V)

120/240

120/240

Rated current (ACV) (AC V)

37.5/18.8

37.5/18.8

3600

3600

Item

Rated speed (rpm) (rpm) G e n e r a t i n g s e t

P hase

Single phase

P ower factor

1.0

E xcitation mode

Self excitation constant constant voltage (AVR) (AVR )

DC output output

12V/8.3A

AC Receptacles

2 120 15A, 1 30A Twistlock, Twistlock, 1 30A 120/240, 120/240,

Structure Structure mode mode

Open frame frame

Coupling method method

Enclosed

Transmission rigid connection

Gross weight lbs. (kg) Overall dimensions LxWxH in (mm) (mm)

Model Item

209 (95)

376 (171)

28.3x19.4x25.6

36.6x20.3x29.7

(720x480x845)

(930x515x755)

KDE5000E

KDE5000TA

Model Type Type

KM186FAG 4-st 4-stro roke ke,,

sing single le-c -cy ylin linder der,

airair-co cool oled ed,,

injection diesel engine

E n g i n e

Max output (kW/rpm)

6.6

Bore x stroke in (mm) (mm)

3.4x2.8 (86x72)

Displacement in (L)

0.418

Cooling Cool ing system

F orced air-cooled system

Lubricating system

P ressure splashing

Lube oil capacity qt. (L)

1.5 (1.65)

Starting Starting system

Recoil/electric

Fuel

E lectric Diesel

F uel tank volume volume gal (L) Run time time at rated load- hrs Low Low oil alarm system system

3.9 (15)

4.2 (16)

8

8.5 included

4

dire direct ct

1-2 KDE500 KDE5000E 0E wiri ng diagram

5

1-3 KDE5000TA wiring diagram

6

1.4 Compon ent Identi fic ation - KDE500 KDE5000E 0E

7

1.5 Compo Compo nent Identifi catio n K DE5000 DE5000T TA

8

1.6 Control panel- KDE5000E OIL ALERT WARNING LAMP

VOLTMETER

START

SWITCH

CIRCUIT BREAKERS

20AMP

120VAC

GROUNDING STUD DUPLEX

30 AMP 120V 120VAC AC RECE RE CEP P TACLE

30 AMP 120/2 120/240 40VAC VAC RE CEP CE P TACLE

1.7 Contr ol Panel KDE5000T KDE5000TA A START

SWITCH

CIRCUIT BREAKERS

DISPLAY DISPLAY PANEL

20A 20A 120VAC DUPLEX

RECEPTACLE

PANEL FUSE

GROUNDING GR OUNDING STUD STU D

30A 30A 120V 120VAC AC RE CEP CE P TACLE

RECEPTACLE

9

30A 30A 120/ 120/24 240V 0VAC AC

1.8 KDE5000T KDE5000TA A Digi tal Dis play pl ay Panel

The The panel anel is desig esign ned to give ive the oper operat ator or precise cise info inforrmation ion regard arding ing generat erator or operation and current loads. Additionally, should the generator experience a condition necessitating shutdown, a fault code appears on the screen. When running, the the green “RUN” UN ” light should be illuminated. Press P ress the function “FUNC UN C” button to change the display. A green light should appear above the digital readout to indicate the current function. You have a choice of voltage (120 or 240), power (VA), Frequency (HZ), total runtime in hours, and starting battery voltage. P anel programming is explained in section section 5.

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1.9 1.9 Serial Serial number and bar code identific ation and loc ation

The The gener enerat ator or ser serial ial number iden identtifie ifies s you yourr part articu icular lar unit and and is import ortant ant when ord ordering ing parts and accessories. The bar code is used by your dealer and Coast Distribution for warranty administration.

The The ser serial ial number for the KDE5000TA is located on the air inlet plate to the left of the diesel injection pump.

The The ser serial ial number for the KGE KG E5000E 5000E can be found found on a

stainless

steel

shroud

surrounding the alternator the right of the engine.

The The bar cod code is fou found in three locations: locations:

on the generator, generator,

on the packing crate or carton, and on the inside cover of the operator’s manual.

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2. SERVICE INFORMATION 2.1 2.1 The importance of prop er servicing

P roper servicing servicing is essential essential to the safety of the the operator and the reliabi reliability lity of the 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 2.2 Important s afety afety 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, repairs, be especially careful 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 the possibility 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 away from rotating 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 ru les

• Use Us e genuine genuine KIP KIP OR or KIP KIP OR-recom OR -recomm mended part parts s and lubricants lubricants or their equivalent equivalents. s. P arts that do not meet meet Kipor’s Kipor’s design specific specifications ations may damage 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

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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. • 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 the end of the bolts or screws or sharp sharp edges and corners, protect the contact part of the harness with a loom or by winding with electrical insulating tape. If the wire harness has a grommet, set the grommet securely. • Take care not to pinch the wire harnesses during installation of a part. If a wire harness has damaged insulation, repair by winding with electrical insulating tape. • When using an electrical tester like a volt/ohm meter or clamp on meter, read the manufacturer’s operating instructions carefully before operating the tester. Be sure that the tester battery is fully charged and the meter is functioning properly

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2.5 Generator Generator Service Standards Winding Winding Main Winding

Standard value of voltage at No load (V) 0.75-0.85

240

S econdary Winding

2.5

135

S ampling ampling Winding

0.5

16

Charge Winding*

2.5

13/13

40-45

70

R otor Winding

*Charge receptacle removed from North American models but windings are present

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2.6 Fasteners and Torque Values

(1) KDE50 KDE 5000E 00E Item

Inner diameter of

Description

screw X length

Torque Value N.M

Lbf

F ront end cover

Hexagonal flange face bolt

M8X25

18

13

Rotor through bolt

Hexagonal Hexagonal flange face bolt

M10X210 M10X210

50

36

fore/back end cover


M6X140

10

7

F rame rame power


M10X45

40

29

M10

40

29

9

7

Tight Tighten en bolt olt of

Hexagonal Hexagonal bolt E arth wire


M6X12

E lectromagnet lectromagnet

Cross Cros s slotted pan head screw

M3X5


M4X8

Anti-hunting bracket


M8X16

20

15

Oil tank


M6X25

9

7

M6

9

7

M6X25

9

7

M6

9

7

Hexagonal Hexagonal bolt Decorating plate

Hexagonal flange face bolt Hexagonal Hexagonal bolt

Carbon Carbon brush


M5X20

Rectification ectification block


M5X20

E arth wire


M5X12

Back cover


M5X12

AVR

Hexagonal bolt

Oil tank assembly


M5X12


M5X8

Nut

M6

9

7


M6X16

9

7

regulator regulator


M6X18

9

7

Battery bracket


M8X16 M8X 16

20

15

Hexagonal Hexagonal bolt

M8

30

22


M6X12

9

7

Nnt

M6

9

7

Butterfly nut

M6

9

7

P anel

M5

Hydraulic pressure

Battery

15

(2) KDE5000TA Item

Inner diameter of

Description

screw X length

Torque Value N.m

Lbf

16 tooth bolt

30

22


M10X225

50

36

front/back end cover


M6X150

10

7

Frame power


M8

18

13


M10

50

36

Earth wire


M6X8

9

7

Muffler


M8

30

22

Fixed


M8X25

20

15


M6X12

9

7


M6X16

9

7

Nut

M6

9

7

AVR


M5X16

Carbon brush


M5X20

Rectification ectification


M5X20

Earth wire


M5X12

Back cover of motor motor


M5X12

Oil tank


M6X20

9

7

Fixed air cleaner

Nut

M6

9

7

Charging regulator regulator


M8X25

20

15

Bracket


M6X12

9

7

Battery bracket


M8X16

20

15


M8

20

15


M6X12

9

7


M6

9

7

Butterfly nut

M6

9

7

British standard3/8 standard3/8 Front end cover Rotor through bolt Tight Tighten en bolt olt of

P anel

Battery

16

2.7 Digi Digi tal Panel Protecti on Values

(1) Low Low oil pressure protectionprotection- oil pressure pressure low for 5s: shutdow shutdown n and display P-01 P -01 (2) Under Under frequency protectionprotection- output frequency =57 =57 Hz for for 10 seconds: seconds: shutdown and display P-02 (3) Over Over frequency protectionprotection- output frequency =65HZ = 65HZ for 10 seconds: seconds: shut shutdown down and display P-02 (4) Under Under voltage voltage protectionprotection- outpu outputt voltage voltage =105V or 210V: shutdown and display display P-03 P-03 (5) Over Over voltage voltage protectionprotection- output output voltage =132V or 264V: shut shutdown down and displ display ay P-03 P-03 (6) Over Over load protection- output output current exceeds 21.2/42.4A: 21.2/42.4A: shutdown and display display P-04 P-04 (7) Charge C harge malfunction malfunction warning: no protection protection but display display P-05 P-05 (8) High temperature- no protection or fault: water cooled engine models only 2.8 Troubleshooting 2.8.1 General symptoms and possible cause

(1) Diesel engine can not start or difficult to start (see engine repair manual) Fault:

Remedy:

Deteriorated Deteriorated diesel oil in fuel oil

Drain the the fuel oil, check and clean

F uel oil is not sufficient

Refill the fuel oil

F uel cock is not at S TART position.

Turn it to S TART position

Fuel delivery line to fuel tank is bent

Check

or pipe is clogged F uel filter filter is clogged The The inje inject ctio ion n pum pump does does not deliv eliver er fuel fuel

Clean Clean or replace Remov Remove e the the high high pres pressu surre fue fuell lin line, e, chec check k for for fuel fuel flow, repair or replace pump

F uel injector does not deliver fuel

Remove emove the fuel injector, check nozzle- clean or replace

The The gov governo ernorr lever lever of eng engine ine throt hrotttle is not not at

Switch on

START position Engine oil filter is clogged causing low oil

Clean or replace

protection Solenoid fuel valve is clogged or does not work

Check the 12V power supply and/or replace

because power is off

solenoid valve

The The gov governo ernorr lev lever of engi engine ne throt hrotttle is def defect ective ive

Check Check and and repl replac ace e as nece necessa ssarry

The The igni ignittion ion swit switch ch fails ails to eng engage age star startter

Check Check bat battery ery con condit dition ion then hen chec check k swit switch ch

Starting motor motor is defective

Replace eplace

Oil alert switch won’t won’t allow ignition ignition

Check Chec k and replace as necessary

The The bat battery ery has has is is dis disch char arge ged d

Check Check bat battery ery and and bat battery ery char charge ge reg regulat ulator or

Valves are improperly improperly adjusted

Check Chec k or adjust valve clearance.

E ngine is seized

Check Chec k

and

observe

the the

engine

rotation, rotation,

disassemble the engine to determine reason for failure.

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(2) Engine speed is unstable, too high or too low (see engine repair manual) Fault:

Remedy:

The The fuel fuel supp supply ly is insu insufffici ficien entt

Adju Adjust st or disas isassem semble ble to clea clean n

Injection pump pump or injector is defective defective

Check Chec k or replace

Generator has an overload or short circuit fault

Repair the the fault

Engine governor spring is faulty faulty

Repair the the fault

Valves out of adjustment

Adjust Adjus t

(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 in multimeter should be “0”

2. The wiring of gauge panel is

Check the wiring harness.

loose 3.

The

connection

of Check or replace receptacle

receptacle is loose or contact broken. Alternator fault

1. The stator leads are not

Check Check the wiring wiring harness

properly connected 2.The four point output terminal

Check Check or replace terminal terminal

is cracked 3. Short, open, or grounded

Check resistance values of all windings.

stator windings

Replace stat s tator or is shorted, open or grounded

4 Loss of magnetism in main

Check AVR

rotor 5. Short, open, or grounded

Check resistance values and replace rotor as

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 stat s tator or and rotor as necessary necess ary..

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(3) AVR AVR fault 1. Voltage can not be regulated

Adjust Adjust or replace AVR

2. Generator set automatically stopped after

Check output voltage, adjust or replace AVR

loading, current setting incorrect 3. Electric component component failed

Replace AVR

4. Sampling signal signal but no exciting output

Check exciting output voltage of AVR. AVR . Adjust Adjus t and or replace.

5. The T he voltage voltage can not be established because

Check that the voltage of main winding is 6 V or

of insufficient residual voltage in the stator

more with with AVR disconnected.

6. Power P ower loss is increased because of higher higher

Check that the voltage of secondary winding should

voltage output of the secondary winding

not greater than 140 VAC

7. The voltage deviation of zero load and full

- Check AVR and stator.

load is too large.

- This may be caused by operating the generator in too high an ambient temperature.

8. Overload shutdown caused by high power

Check inductive loads for low power factor and

factor loading

adjust size 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) Control panel fault Fault:

Remedy:

1. No display on screen.

- Check 12V power supply of the generator and check

2. Displays wrong code.

wiring .

3. Generator cannot start.

- replace screen

19

2.8. 2.8.2 2

Troubleshootin g flow charts

(1) Hard starting

20

(2) No AC voltage

21

(3) No Voltage Voltage Regulat R egulation ion

22

(4) Generator shutdown

23

3. GENERA GENER ATOR REPAIR RE PAIR 3.1 Start switch

Check: Circuit Circuit should be closed when switched switched on. Circuit C ircuit should be open when when switched switched off. In starting position the circuit should be closed. 1

2

3

OFF OF F ON

----------

---------

START

----------

----------

----------

.

24

4

5

6

7

---------

-------------------

----------

-------------------

3.2

Voltm ol tmeter eter (KGE5000E) (KGE5000E)

Check generator output with a voltmeter. The reading should agree with the voltmeter. If the voltmeter has no output or it varies with the generator output, test and replace as necessary.

3.3 Circu it B reaker

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.

25

3.4 Oil alert PCB and pressu re swi tch

26

27

28

3.5

Generator

3.5.1 Check

(1) Front F ront end 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. Norm Normal al measured measured resistance resistance should comply with section 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 should be smooth without without any defect or dis distort tortion. ion. The The semici semicircle rcle of the the center center boss should be clear. In case case of distortion distortion replace the clip ring (5) Through bolt: tightening tightening torque is 37-41 Lbf (50-55 N.m). N.m). This is essential essential to ensure the generator won’t be damaged by scrubbing of the rotor and stator. (6) Stator: Check the extern external al enamel covered wire for defects after disass disassemb embly ly 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

29

(b) Secondary or sub winding: Locate the 4 pin connector at the top of the stator. Check the resistance b (c) Sampling winding: On the same 4 pin connector, check the resistance between the (d) Charge winding: Find the 4 pin connector at the top of the stator. There are only two (7) Carbon brush: There should be no open circuit between lug and pole of the carbon brush and no no short circuit between between the the two two poles. Check the the brushes for wear. wear. If the the brush wear is uneven or the length is less than 0.12 in. (3mm) (8) Rear R ear end cover: check for cracking. 3.5.2 3.5.2 Disassembl y

(1) Open the rear end cover for for open frame generator. generator. Rem R emove ove the the cabinet, cooling cooling plate, left and right side plates, and muffler for TA model. (2) Remove the alternator assembly with the harness. With the TA model, you must remove the induced draft hood to get to the harness. (3) Remove emove 4xM6x175M 4xM6x175M bolt from the rear end cover. (4) Remove emove the stator. stator. (5) Secure the rotor to to prevent it from dropping dropping and remove remove the 10mm flange flange bolt. (6) Remove emove the rotor with a puller. puller. 3.5.3 3.5.3

Rotor Installatio n

Caution: Remove any dust and oil pollution from the crankshaft and rotor. Check the resistance of the new part before installation. 1)

Insert Insert the semicircle semicircle clip ring into key groove.

2)

Install Install the rotor on the crankshaft.

(3) Secure the rotor wit with h a strap strap wrench wrench and tighten tthe he 10mm 10mm flange bolt: tightening 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

30

Lbf (10-13 N.m) • The correct spacing is 0.020+/-0.004 in (0.25 +/- 0.1 mm)

31

4. Electri Electri cal Compo Compo nent Illust ration s 4.1 Receptacle wirin g

32

4.2 AVR AVR Adjus tment

33

4-3 Battery Charge Regulato Regulato r

4.4 Current Transfo rmer

34

35

4-5 Rotor Checking

Note: u se t he values for the K DA6700T DA6700TA A for bot h t he KDE5000 KDE5000E E and KDE5000T KDE5000TA A

36

4-6 Stator Test Points CHARGE WINDING PLUG

SECONDARY AND SENSING WINDING PLUG

CARBON BRUSH

L1 L2 R1 R2

\

37

4-7 Main Stator Stator Winding Check

Note: u se t he values for the K DA6700T DA6700TA A for bot h t he KDE5000 KDE5000E E and KDE5000T KDE5000TA A

38

4.8 Stator Secondary Winding and Sampling Winding Check

Note: u se th e values for the K DA6700T DA6700TA A for bot h t he KDE5000 KDE5000E E and KDE5000T KDE5000TA A The color of t he secondary secondary wi nding my b e blue instead instead of g reen reen

39

4.9 Charge Winding Check

Note: u se t he values for the K DA6700T DA6700TA A for bot h t he KDE5000 KDE5000E E and KDE5000T KDE5000TA A 4-10 Carbon brush check

40

5. K DE5000TA DE5000TA DISPL AY PANEL 5.1

Setting

The The dig digit ital disp isplay lay panel anel is pr preset set at the fac facttory ory. If it becom ecomes n nec ece essar ssary to rep repla lace ce the panel, it will have to be programmed before installation. (1) Connect the the ribbon cable to the the new display display unit. unit. Be careful not to to twist twist the the cable (2) Remove the back cover of the panel. (3)

P ress and hold down the F unction “FUNC UNC ” and turn turn the ignition switch ON. ON . Wait 5

seconds to enter the program (4) Locate Locate the the five position DIP switch board and and put the DIP switches switches in the the following position position to set the the Proper P roper voltage voltage and frequency: 1 2 3 ON

X

OFF

X

4

5

X

X

X

(5) The three three position DIP switch board is factory factory set but make sure the the settings settings are as follows: 1 ON OFF

X

41

2

3

X

X

Kipor KDE5000E 5000TA Service Manual[1]

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