KIPOR Diesel Generator Service Manual PDF
Preview KIPOR Diesel Generator Service Manual
DIESEL GENERATOR SINGLE-PHASE: K DE2200X/E K DE3500X/E/T K DE5000X/E/T K DE6500X/E/T/TA K DE6700T/TA K DA6700TA/TAO THREE-PHASE: K DE6500X3/E3/T3 K DE6700T3/TA3 K DA6700TA3/TAO3 MAINTENANCE MANUAL PREFACE WARNING Please read this instruction and ensure understand all regulations concerning handling, check and maintenance thoroughly prior to application. Failure to follow this instruction may cause serious accidents. Incorrect operation is likely to lead accidents. Operate and maintain the machine on the basis of thorough understanding of this instruction. Place this instruction in the fitting box or near machine after reading because it is regularly needed. If this introduction is lost or damaged, please order one from local KIPOR dealer. Please provide this introduction to another user whom machine will be transferred to. Machine may be improved or modified. Therefore actual conditions may be different from this introduction. If you have any doubt, please consult local KIPOR dealer. Machine is the special diesel generator for ground application. Safety information contained in this introduction are extremely important. Please read and understand it. Content 1.Technical Specifications 1.1Main Technical Parameters 1.2Power vs Voltage Diagram of Generating Set Output Characteristic 1.3Overall Dimension Drawing 1.4Electric Principle and Wiring Diagram for Various Models of Generating Set 2.Important Information 2.1Versions Description 2.2Safety 2.3Importance of Proper Maintenance 2.4Important Safety Precautions 2.5Maintenance Regulations 2.6Electric Precautions 2.7Parts Name 2.8Location of Generating Set Series Number 2.9Maintenance Norm for Generating Set 2.10 Torque List (Torque Value) 2.11 Factory Settings of Generating Set 2.12 Troubleshooting Open-shelf Diesel Engine and Quiet Generating Set 2.12.1General Symptom and Possible Cause 2.12.2Flow Chart of Troubleshooting 3.Maintenance Checks 3.1Service List 3.2Checks 3.2.1Check Fuel Oil 3.2.2Check Engine Oil 3.2.3Check Air Cleaner 3.2.4Check Starting Performance of Generating Set 3.2.4.1Recoil Starting 3.2.4.2Electric Starting 3.2.5Check Battery 3.2.6Checks during the Running 3.2.6.1 Check A.C.Output Characteristic 3.2.6.2 Check D.C 3.2.7 Check Overload Operation 3.2.8 Check Stopping of Generating Set 4.Maintenance 4.1Oil-line and intake/exhaust parts 4.1.1Engine Oil 4.1.2Replace Engine Oil 4.1.3Oil Tank / Fuel Oil Filter 4.1.4Oil Pipe / Oil Pump 4.1.5Air Cleaner 4.1.6Muffler 4.2Control Panel 4.2.1A.C. Receptacle 4.2.2D.C. Receptacle or Terminal Post 4.2.3Starting Switch 4.2.4Voltmeter 4.2.5Air Breaker 4.2.6Engine Oil Alerting Apparatus 4.3Generator 4.3.1Generator 4.3.2Installation of Rotor 4.3.3Stator 4.4Cabinet 4.4.1Right Plate 4.4.2Left Plate 4.4.3Cabinet 4.4.4Cabinet Transformer 4.4.5Chassis 5.Service of Intelligent Control Panel for KDE6700TA/TA3 5.1Setting 5.2Check 5.3Maintenance 5.4Parameter Setting List 5.5Diagram of Switch Position for Address Setting 1. SPECIFICATIONS 1-1 Main technical Specifications Model KDE3500X KDE3500E KDE6500X KDE6500E KDE3500T KDE3700T KDE2200X KDE2200E Generating Set Rated frequency (Hz) Rated output power (kVA) Max. power (kW) Rated current ( A) Rated rotation speed (r/min ) Phase Power factor (cos ) Excitation type DC output Generator structure Generator Insulation grade Pole number 50 50 50 50 60 60 60 3.2 3.8 5 5.5 3.2 3.8 230 3000 240/120 3600 3000 3600 3600 3600 3000 3000 230 230 230 240/120 240/120 240/120 Single phase Self-excitation 12V/8.3A 60 50 60 1.7 2 230 3000 2.2 240/120 3600 Single phase 3.2 3.8 Rated voltage (V) 7.4 12.2 13.8/27.5 19.6 20.8/41.7 12.2 13.8/27.5 8.3/16.7 12.2 13.8/27.5 2.8 4.5 2.8 2.8 3.3 3.3 3.3 5 2 Single phase Single phase Single phase 1 1 1 1 1 One bearing, Self ventilation Rotation magnetic field, rotor chute B B B B 2 2 2 2 2 KM170F KM178F KM186F KM178F KM178F One cylinder, 4 choke, air cooled, inlined, diesel engine Engine model Engine type Bore choke (mm) 70 55 78 62 86 72 78 62 78 62 Model KDE3500X KDE3500E KDE6500X KDE6500E KDE3500T KDE3700T KDE2200X KDE2200E Structure type Engine Displacement(L) Compression rate Rated power kW/(r/min) Fuel model Lubricating oil model Voltage deviation at steady state Frenquency rate Voltage wave type distortion rate(zero load) Insulation resistence(at cold station) Fuel consumption rate(g/kw.h) Capability of fuel tank(L) Continuous running time(Hr) Overall dimension(mm) (L W H) Net weight (kg) Starting type Noise level(dBA/7m)(at rated load) 0.211 20:01 2.5/3000 2.8/3600 0.296 20:01 0.418 19:1 0.296 20:01 0.296 20:01 3.7/3000 4.0/3600 5.7/3000 6.3/3600 3.7/3000 4.0/3600 3.7/3000 4.0/3600 370 15 22 640 480 530 X:53 E:60 77 Open frame o# (summer), -10# (winter),-35# (chill cold) diesel SAE10W30(above CC grade) 2.5% 5% Single phase 5% Three-phase 8% 2M X:Recoil starter; E:Recoil starter/Electric starter 370 15 14 640 480 530 70 77 Open frame 360 15 8 720 492 650 X:95 E:100 79 Open frame 370 16 14.5 830 532 740 140 70 Silent 370 16 14.5 845 547 742 150 79 Silent Recoil starter /Electric starter X:Recoil starter; E:Recoil starter/Electric starter Electric starter Electric starter Generating set Model KDE6700T/TA/TAO KDE6500X3/E3/T3 KDE6700T3/TA3/TAO3 KDE6500T Generating Set Rated frequency (Hz) Rated output power (kVA) Max. power (kW) Rated current ( A) Rated rotation speed (r/min ) Phase Power factor (cos ) Excitation type DC output Generator structure Generator Insulation grade Pole number Single phase Self-excitation 12V/8.3A Rated voltage (V) Single phase 1 1 One bearing, Self ventilation Rotation magnetic field, rotor chute B B B 2 2 2 2 KM186F KM186F KM186F KM186F One cylinder, 4 choke, air cooled, inlined, diesel engine Engine model Engine type Bore choke (mm) 86 72 86 72 86 72 86 72 50 50 50 60 60 6kVA 7kVA 230 3000 240/120 3600 3000 3600 3600 3000 400/230 400/230 416/240 416/240 60 50 60 4.5 5 230 3000 5.5 240/120 3600 Three phase 19.6 19.6 7.9 20.8/41.7 7.9 5.5kVA 6.3kVA 5 Three phase 0.8(lag) 0.8(lag) 20.8/41.7 4.5 5 5.5 5 6kVA 7kVA 5.5kVA 6.3kVA 8.7 8.7 No 12V No 12V B Note: Explaination for generating set model: KDE is the generating set, 2200 is the set model. Function code: X is recoil starter E is electric starter set, T is electric starter silent set, A is digital control panel set, O is automatic starter and automatic change function with ATS. A, O code only used for above 6700 set model. Structure type Engine Displacement(L) Compression rate Rated power kW/(r/min) Fuel model Lubricating oil model Voltage deviation at steady state Frenquency rate Voltage wave type distortion rate(zero load) Insulation resistence(at cold station) Fuel consumption rate(g/kw.h) Capability of fuel tank(L) Continuous running time(Hr) Overall dimension(mm) (L W H) Net weight (kg) Starting type Noise level(dBA/7m)(at rated load) 0.211 20:01 5.7/3000 6.3/3600 0.296 20:01 0.418 19:1 0.296 20:01 5.7/3000 6.3/3600 5.7/3000 6.3/3600 5.7/3000 6.3/3600 360 15 8 910 530 740 165 70 Silent o# (summer), -10# (winter),-35# (chill cold) diesel SAE10W30(above CC grade) 2.5% 5% Single phase 5% Three-phase 8% 2M 370 15 14 915 547 742 177 70 Silent 360 15 8 910 530 740 165 70 Silent 370 16 14.5 915 547 742 177 70 Silent Electric starter Generating set Model KDE6700T/TA/TAO KDE6500X3/E3/T3 KDE6700T3/TA3/TAO3 KDE6500T Electric starter Electric starter Electric starter Main technical specification of single-phase and three-phase generator sets Model Rated frenquency (Hz) Rated output(kW) Rated output (V) Rated current(A) Phase Poweer factor (cos ) Rated welding current(A) Welding work voltage(V) Welding work condition (DC) Welding and generating set Generating work condition (AC) Welding voltage at zero load(V) Welding continous load rate(%) Diameter of welding rod (mm) Adjusting range of welding current (A) 50 2.8 230 12.2 60 3 240 12.5 50 2.8 230 12.2 60 3 240 12.5 Single 1 70-75 160 25-35 60% 30-180 1.6-4.0 Single 1 60-65 160 26 60% 50-180 1.6-4.0 KDE6500XW/EW KDE6700TW Rated rotation speed r/min Exciation type Rectify type Connecting type Insulation grade Voltage deviation at steady state Frenquency rate Motor Pole number Engine model Engine type Displacement(ml) Bore x stroke(mm) Compression rate Rated power Kw/(r/min) Fuel model Lubricating oil model Fuel consumption(g/kw.h) Oil tank capacity (L) Continuous running time(h) Overall dimension(L W H)[mm(in)] Net weight[kg(1bs)] Starting type Noise level [db(A)@7m](at rated load) Structure X X Engine Set Voltage wave type distortion rate(zero load) 3000 36000 3000 36000 Self exciation and automatic voltage adjusting(AVR) IGBT+three-phase rectify bridge(PWM ) IGBT+three-phase rectify bridge(PWM) Single bearing 2.5% 5% 5% Rotor chute band damping winding 2 KM186FAG 418 86X72 19 5.7/3000 6.3/3600 2 KM186FAG 418 86X72 19 5.7/3000 6.3/3600 Inlined .single .4-stroke.air cooled Inlined .single .4-stroke.air cooled SAE10W30 (above CC grade) 360 15 6.5 840x535x650 X 115 E 120 360 16 T:7 915x547x742 188 75 EW/XW Open-frame TW Silent 0#(Summer) -10#(Winter) -35#(Chill cold)Light diesel XW: Recoil starter EW/TW: Electric starter 70 B B 1-2 The set power and voltage characteristic curves The following curves indicate generator performance at average conditions. The performance may vary according to ambient temperature. Before generator set leave the factory, voltage is set beyond rated voltage. When generator set start running, output voltage should be equal to rated output, as load time increase, rated voltage decrease. (1) AC external characteristic curves of KDE2200X/E generator sets (2)AC external characteristic curves of KDE3500X/E generator sets AC ouput voltage V 130 120 110 100 0 2 4 6 8 10 12 14 16 18 20 KDE2200X/E 120V 250 240 230 220 0 2 4 6 8 10 KDE2200X/E 240V 0 2 4 6 8 10 KDE2200X/E 18 16 14 12 10 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 KDE3500X/E 120V 130 120 110 100 KDE3500X/E 240V 0 2 4 6 8 10 12 14 16 18 250 240 230 220 KDE3500X/E 18 16 14 12 10 0 2 4 6 8 10 130 120 110 100 KDE6500X/E 120V 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 250 240 230 220 0 2 4 6 8 10 12 14 16 18 20 22 KDE6500X/E 240V KDE6500X/E 0 2 4 6 8 10 18 16 14 12 10 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 KDE6500X/E 120V 130 120 110 100 250 240 230 220 18 16 14 12 10 (3)AC external characteristic curves of KDE6500X/E generator sets (4)AC external characteristic curves of KDE6500T generator sets 0 2 4 6 8 10 12 14 16 18 20 22 KDE6500X/E 240V KDE6500X/E 0 2 4 6 8 10 (5)AC external characteristic curves of KDE6700T/TA generator sets (6)AC external characteristic curves of KDE6700T3/TA3 generator sets (7)AC external characteristic curves of KDE6500EW/XW generator sets 130 120 110 100 KDE6700T/TA 120V 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 250 240 230 220 0 2 4 6 8 10 12 14 16 18 20 22 KDE6700T/TA 240V KDE6700T/TA 0 2 4 6 8 10 18 16 14 12 10 KDE6500EW/XW 75 70 65 60 55 50 45 40 35 30 25 180 160 120 100 80 60 40 432 416 400 KDE6700T3/TA3 416V/240V KDE6700T3/TA3 250 240 220 0 2 4 6 8 250 240 230 220 0 2 4 6 8 0 2 4 6 8 10 12 0 KDE6500EW/XW 1-3 Overall dimension drawing Unit mm KDE2200X/E generator sets KDE3500X/E generator sets KDE6500X/E/X3/E3 generator sets KDE6500T/T3 generator sets KDE6700T/TA/T3/TA3 generator sets KDE6500XW/EW generator sets 930 KDE3500X/E&KDE6500X/E generator sets KDE3500X KDE6500X Single voltage output, electric schematic diagram the same (Yellow) (Black) Voil pressure indicator light Voil pressure protection Stop electromagnet Charging winding Main winding Main winding Sampling winding Excitation winding Assistant excitation winding Air switch Voltmeter Over loading protection Double voltage simultaneousant put current mutual- inducator 1-4 Wiring diagrams of: KDE2200X/E generator sets KDE2200X single voltage output, electric schematic diagram Low oil pressure protection Low oil pressure indicator light Charging winding Air switch Single voltoge output Excitation winding Assistant excitation winding Main winding Main winding Stop electomagnet Voltmeter Sampling winding KDE2200X Double voltage selective output, electric schematic diagram Low oil pressure protection Low oil pressure indicator light Stop electomagnet Charging winding Sampling winding Main winding Main winding Excitation winding Assistant excitation winding Breaker Output Output Voltmeter indicates 240V & 20V respectively Voltmeter indicates 120V output Low oil pressure protection Low oil pressure indicator light Stop electomagnet Charging winding Sampling winding Main winding Main winding Excitation winding Assistant excitation winding Air switch KDE2200X Double voltage simultaneous output, electric schematic diagram Output Air switch Air switch Output Output KDE3500X KDE6500X Double voltage selective output electric schematic diagram the same Low oil pressure dicator light Low oil pressure protection Stop electromagent Assistant excitation winding Excitation winding Main winding Main winding Charging winding Sampling winding Current mutual-inducator Voltmeter indicates Excitation winding Breaker Output Output Protect Overloading KDE3500X KDE6500X Double voltage simultaneous output, electric schematic diagram Voil pressure indicator light Voil pressure protection Stop electromagnet Charging winding Main winding Main winding Sampling winding Excitation winding Assistant excitation winding Air switch Over loading protection Current mutual- inducator Air switch Air switch Output Output Voltmeter mdicates KDE3500E KDE6500E Single roltage output, electric schematic diagram the same Red Sampling winding Black Yellow & Green Green White Green Charging regulator Yellow Start relay Start electric motor White Yellow & Green Blue Blue Red Yellow Black Black Protection Low oil pressure switch BL KDE3500E KDE6500E Double voltage selective output, electric schematic diagram the same Red Sampling winding Yellow&Green Charging regulator Start relay Start electric motor White Black Protection Low oil pressure switch Red Brown Blue Voltmeter indicates 240V & 20V respectively Output Output Black Black Blue Blue Yellow Red Yellow White Yellow & Green Breaker Green Green Protection Low oil pressure switch Output Output Voltmeter indicates Air switch Air switch Air switch Black Black Start relay Start electric motor Blue Blue Yellow Red White Yellow & Green Red Sampling winding Black Brown Blue Green White Charging regulator Yellow & Green KDE3500E KDE6500E Double voltage simultaneous output, electric schematic diagram the same KDE3500T&KDE6500T generator sets KDE3500T KDE6500T Single voltage output, electric schematic diagram Red Electric switch lock Start electromagnet Storage battery Throttle electromagnetic valve Start electricmotor Voil pressure protection Flywheel generator Rregulator Voil pressure indicator light Black Yellow Main winding Main winding Sampling winding Excitation winding Assistant excitation winding Electric switch lock Start electromagnet Storage battery Throttle electromagnetic valve Start electric-motor Flywheel generator regulator Sampling winding Brown Black Red Blue Voltmeter mdicates 240V & 20V Output Output Voil pressure indicator light Red Breaker Yellow & Green Voil pressure protection KDE3500T KDE6500T Double voltage selective output, electric schematic diagram Electric switch lock Storage battery Start electricmotor Flywheel generator regulator Sampling winding Brown Air switch Voltmeter mdicates Air switch Air switch Output Output Yellow & Green Voil pressure indicator light Voil pressure protection Black Red Blue Start electromagnet KDE6500T KDE3500T Double voltage simultaneous output, eletric schematic diagram KDE6700TA generator sets KDE6700TA Single voltage output, electric schematic diagram Assistant excitation winding Excitation winding Current mutual-inducator Sampling winding Main winding Throttle electromagnetice valve Flywheel generator Regulator Storage battery Yellow&Green Red Bla ck Red Current sampling Starting electromagnet Starting electric motor Blue Intellignet board conroller Charging winding Blue Blue Fuse OFF-ON relationship list of electic switch lock Red Black Direct current socket Red Black Voltage sampling converter Grey Grey White White Yellow Yellow Green Orange Flywheel AC Brown Purple Protect Red Blue Red Fuse White Fuse Simple intellagent screen Breaker Red Black Voltage sampling Voltage sampling Green KDE6700TA Doulbe voltage selective output electric schematic diagram Current mutual-inducator Sampling winding Main winding Assistant excitation winding Excitation winding Throttle electromagnetice valve Flywheel generator Regulator Storage battery Red Black Current sampling Starting electromagnet Starting electric motor Blue Intellignet board conroller Charging winding Blue Blue Fuse OFF-ON relationship list of electic switch lock Red Black direct current socket Black Red Breaker Blue Red Black Red Black Voltage sampling converter Grey Grey Grey Grey Green White White Yellow Yellow Green Orange Flywheel AC Brown Purple Protect Red Blue Red Fuse White White Fuse Simple intellagent screen Output Output Voltage sampling Brown KDE6700TA Double voltage simulataneous output, electric schematic diagram Current mutual-inducator Sampling winding Main winding Assistant excitation winding Excitation winding Main winding Current sampling Red Black Grey Grey Red Red Green White Fuse White Fuse Breaker Breaker Red Black Single socket Black Single socket Yellow&Green Red Black Fuse Blue Blue Charging winding Red D socket irect current OFF-ON relationship list of electic switch lock Voltage Sampling Simple intellagent screen Intelligent board controller Blue Purple Brown Starting electromagnet Starting electric motor Storage battery Regulator Yellow-Green Orange Throttle electromagnetice valve Flywheel generator White Yellow Voltage sampling converter Black Red Red Blue Red KDE6500EW generator sets Assistant winding Excitation winding Sampling winding Red OFF-ON relationship list of electic switch lock Low oil pressure switch Red Black Orange Control modele Black Yellow Green Protect Protect Yellow Black Blue Absorptron board Plastic sheath Drive board Plastic sheath Red Blue Plastic sheath Generate electricity winding R BL O Welding output KDE6500EW Both manual start KDE6500EW Double vltage selective output with electric start Electric schematic diagram Voltage selective switch Excitation winding Assistant winding Generating winding Sampling winding Generating winding Red Black Breaker Breaker On-off relationship list of electric switch lock Green Green Charging regulator White Yellow & Green Start relay Start electric motor Low oil pressure switch Black Blue Yellow Yellow White Protection Absorption board red/black blue/black white/black Welding output Plastic sheath Plastic sheath Red Blue Driving board Control modele Plastic sheath Red Black Red Excitation winding Assistant winding Generating winding Sampling winding Generating winding Red Black Brown Breaker On-off relationship list of electric switch lock Green Green Charging regulator White Yellow & Green Start relay Start electric motor Low oil pressure switch Black Blue Yellow Yellow White Protection Absorption board red/black blue/black white/black Welding output Plastic sheath Plastic sheath Red Blue Driving board Control modele Plastic sheath Red Black Brown Breaker Blue Blue Red KDE6500XW Manual & electric start electric schematic diagram KDE3500E3/T3 & 6500E3/T3 generator sets KDE3500E3 KDE6500E3 Electric schematic diagram the same Excitation winding Assistant winding Sampling input Main winding Breake Yellow Green Red Black Three-phases socket Yellow Green Red Black Yellow & Green Yellow & Green Single-phase socket Protection Charging regulator Start relay Start electric motor Low oil pressure switch Black Black Blue Blue Red Yellow Yellow & Green Yellow White White Green Green Electric switch lock Start electromagnet Storage battery Start electric-motor Flywheel generator regulator Sampling input Main winding Voil pressure indicator light Red Breaker Yellow & Green Voil pressure protection Low oil alarm system Winding Black Green Yellow Green Red Black Yellow & Green Excitation winding Vice winding Single receptacle Three-phases receptacle KDE3500T3 KDE6500T3 Electric schematic diagram the same
The list of books you might like
