KIPOR POWER PRODUCTS CO.

, LTD
GENERATOR SHOP MANUAL

KDE5000E
KDE5000TA

The Coast Distribution System, Inc.

January, 2007
 PREFACE

This manual covers the construction, function and servicing procedure of the 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.
There is a separate manual to cover overhaul, repair and troubleshooting of the KM186FA
diesel 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.

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
1.1 Specifications ....................................................................................................4
1.2 KDE5000E wiring diagram................................................................................5
1.3 KDE5000TA wiring diagram ............................................................................6
1.4 Component Identification- KDE5000E..............................................................7
1.5 Component Identification- KDE5000TA ..........................................................8
1.6 Control Panel- KDE5000E ..............................................................................9
1.7 Control Panel- KDE5000TA .............................................................................9
1.8 KDE5000TA Digital Display Panel ...................................................................10
1.9 Serial number and bar code location ..............................................................11
2. Service Information .....................................................................................................12
2.1 The importance of proper servicing .................................................................12
2.2 Important safety precautions.............................................................................12
2.3 Service rules ....................................................................................................12
2.4 Electrical precautions ......................................................................................13
2.5 Generator Service Standards............................................................................14
2.6 Fasteners and torque values ..........................................................................15
2.7 Digital panel protection values ........................................................................15
2.8 Troubleshooting ...............................................................................................15
3. Generator Repair..........................................................................................................23
3.1 Start switch ......................................................................................................23
3.2 Voltmeter .........................................................................................................24
3.3 Circuit breaker .................................................................................................24
3.4 Oil alert ..............................................................................................................25
3.5 Generator ........................................................................................................28
4. Electrical Component Illustrations................................................................................30
4.1 Receptacle wiring ............................................................................................30
4.2 AVR adjustment.................................................................................................31
4.3 Battery charge regulator ..................................................................................32
4.4 Current transformer...........................................................................................32
4.5 Rotor checking ................................................................................................34
4.6 Stator test points ..............................................................................................35
4.7 Main stator winding check.................................................................................36
4.8 Stator secondary and sampling winding check ...............................................37
4.9 Charge winding check .....................................................................................38
4.10 Carbon brush check........................................................................................38
5. KDE5000TA display panel ..........................................................................................39

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1. SPECIFICATIONS AND DATA
1.1 Specifications

Model
KDE5000E KDE5000TA
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
Generating set

Power factor 1.0

Excitation mode Self excitation constant voltage (AVR)
DC output 12V/8.3A
AC Receptacles 2 120 15A, 1 30A Twistlock, 1 30A 120/240,
Structure mode Open frame Enclosed
Coupling method Transmission rigid connection
Gross weight lbs. (kg) 209 (95) 376 (171)
Overall dimensions LxWxH in (mm) 28.3x19.4x25.6 36.6x20.3x29.7
(720x480x845) (930x515x755)

Model
KDE5000E KDE5000TA
Item
Model KM186FAG
Type 4-stroke, single-cylinder, air-cooled, direct
injection diesel engine
Max output (kW/rpm) 6.6
Bore x stroke in (mm) 3.4x2.8 (86x72)
Displacement in (L) 0.418
Engine

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

4
1-2 KDE5000E wiring diagram

5
1-3 KDE5000TA wiring diagram

6
1.4 Component Identification- KDE5000E

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1.5 Component Identification KDE5000TA

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1.6 Control panel- KDE5000E
OIL ALERT WARNING LAMP VOLTMETER

START SWITCH

CIRCUIT BREAKERS

20AMP 120VAC

GROUNDING STUD

DUPLEX

30 AMP 120VAC RECEPTACLE 30 AMP 120/240VAC RECEPTACLE

1.7 Control Panel KDE5000TA

START SWITCH

CIRCUIT BREAKERS

DISPLAY PANEL

20A
120VAC DUPLEX

RECEPTACLE

PANEL FUSE

GROUNDING STUD 30A 120VAC RECEPTACLE 30A 120/240VAC

RECEPTACLE

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1.8 KDE5000TA Digital Display Panel

The panel is designed to give the operator precise information regarding generator
operation and current loads. Additionally, should the generator experience a condition
necessitating shutdown, a fault code appears on the screen.

When running, the green “RUN” light should be illuminated. Press the function “FUNC”
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.

Panel programming is explained in section 5.

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1.9 Serial number and bar code identification and location

The generator serial number identifies your particular unit and is important when ordering
parts and accessories. The bar code is used by your dealer and Coast Distribution for
warranty administration.

The serial number for the

KDE5000TA is located on the
air inlet plate to the left of the
diesel injection pump.

The serial number for the

KGE5000E can be found on
a stainless steel shroud
surrounding the alternator the
right of the engine.

The bar code is found in three

locations: on the 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 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 Kipor’s design specifications may damage the engine.
• Use the special tools designed for the product.
• Always install new gaskets, O-rings, etc. when reassembling components.
• 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 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
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 Service Standards

Winding Resistance standard (Ω) Standard value of voltage at No load (V)

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

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2.6 Fasteners and Torque Values
(1) KDE5000E

Inner diameter of Torque Value

Item Description
screw X length
N.M Lbf
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 diameter of Torque Value
Item Description
screw X length N.m Lbf
British standard3/8
Front end cover 16 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 Digital Panel Protection Values
(1) Low oil pressure protection- oil pressure low for 5s: shutdown and display P-01
(2) Under frequency protection- output frequency = 57 Hz for 10 seconds: shutdown and
display P-02
(3) Over frequency protection- output frequency = 65HZ for 10 seconds: shutdown and
display P-02
(4) Under voltage protection- output voltage = 105V or 210V: shutdown and display P-03
(5) Over voltage protection- output voltage = 132V or 264V: shutdown and display P-03
(6) Over load protection- output current exceeds 21.2/42.4A: shutdown and display P-04
(7) Charge malfunction warning: no protection but display 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 diesel oil in fuel oil Drain the fuel oil, check and clean
Fuel oil is not sufficient Refill the fuel oil
Fuel cock is not at START position. Turn it to START position
Fuel delivery line to fuel tank is bent Check
or pipe is clogged
Fuel filter is clogged Clean or replace
The injection pump does not deliver fuel Remove the high pressure fuel line, check for fuel
flow, repair or replace pump
Fuel injector does not deliver fuel Remove the fuel injector, check nozzle- clean or
replace
The governor lever of engine throttle is 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 governor lever of engine throttle is defective Check and replace as necessary
The ignition switch fails to engage starter Check battery condition then check switch
Starting motor is defective Replace
Oil alert switch won’t allow ignition Check and replace as necessary
The battery has is discharged Check battery and battery charge regulator
Valves are improperly adjusted Check or adjust valve clearance.
Engine is seized Check and observe the engine 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 fuel supply is insufficient Adjust or disassemble to clean
Injection pump or injector is defective Check or replace
Generator has an overload or short circuit fault Repair the fault
Engine governor spring is faulty Repair the fault
Valves out of adjustment Adjust

(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 the wiring harness
properly connected
2.The four point output terminal Check or replace terminal
is cracked
3. Short, open, or grounded Check resistance values of all windings.
stator windings Replace stator 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 stator and rotor as necessary.

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(3) AVR fault

1. Voltage can not be regulated Adjust or replace AVR

2. Generator set automatically stopped after
loading, current setting incorrect
3. Electric component failed
4. Sampling signal but no exciting output
5. The voltage can not 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.
8. Overload shutdown caused by high power
factor loading
Check output voltage, adjust or replace AVR
Replace AVR
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 greater than 140 VAC
- Check AVR and stator.
- This may be caused by operating the generator in
too high an ambient temperature.
Check inductive loads for low power factor and
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

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2.8.2 Troubleshooting flow charts
(1) Hard starting

20
(2) No AC voltage

21
(3) No Voltage Regulation

22
(4) Generator shutdown

23
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 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 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.

25
3.4 Oil alert PCB and pressure switch

26
27
28
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 won’t 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

29
0.75 to 0.85 Ω between L1 and L2 and R1 and R2
(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 Ω.
(c) Sampling winding: On the same 4 pin connector, check the resistance between the
two yellow wires. The value is 0.5 Ω.
(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 Ω.
(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)
(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 TA model, you must
remove the induced draft hood to get to the harness.
(3) Remove 4xM6x175M bolt 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.

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

30
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

32
4.2 AVR Adjustment

33
4-3 Battery Charge Regulator

4.4 Current Transformer

34
35
4-5 Rotor Checking

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

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 Winding Check

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

38
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 my be blue instead of green

39
4.9 Charge Winding Check

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

4-10 Carbon brush check

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5. KDE5000TA DISPLAY PANEL
5.1 Setting

The digital display panel is preset at the factory. If it becomes necessary to replace the
panel, it will have to be programmed before installation.
(1) Connect the ribbon cable to the new display unit. Be careful not to twist the cable
(2) Remove the back cover of the panel.
(3) Press and hold down the Function “FUNC” and turn the ignition switch ON. Wait 5
seconds to enter the program
(4) Locate the five position DIP switch board and put the DIP switches in the following
position to set the Proper voltage and frequency:
1 2 3 4 5
ON X X X
OFF X X

(5) The three position DIP switch board is factory set but make sure the settings are as
follows:
1 2 3
ON X X
OFF X

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