WUXI KIPOR POWER CO., LTD.

GASOLINE
GENERATOR

KGE12E
KGE12E3

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 PREFACE
Congratulation and thank you for your purchase of our unit; our aim is to
provide a high-quality generator set to achieve customer satisfaction,
and we are confident that your choice will be justified.

This manual, dealing with the generator side of the unit, gives all the
basic information to ensure satisfactory and reliable operation of your
unit.

Please use this manual as a companion to the other manual covering the
engine side.

CAUTION
1. Use SAE 10W-30 Lubrication oil. After the first oil change at 10
hours operation.
2. Do not connect the generator output to commercial AC outlets.
3. For information about the engine operation and maintenance,
please see our engine's manual.

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 1. NAMES OF IMPORTANT PARTS AND COMPONENTS
CONTENTS

1. Names of Important Parts and Components 1 KGE12E Control Panel

2. Preparatory Steps for Operation 4

Voltmeter Ammeter
Engine switch
5 Fre. meter
3. Safety Precations for Servicing
Single phase receptacle (25A)

Main switch
4. Warm-up Procedure 6
Hour counter

5. Starting-up Procedure 7
AC Output terminals

6. Stop Procedure 7

7. Simplified Troubleshooting Guide 8

8. Malfunction and Countermeasures 9

9. Electrical Skeleton Diagram 10

10. APPENDIX 12

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 Engine

Specification

MODEL KGE12E KGE12E3

AC Prime 8.5kVA 10.5kVA
50Hz
OUTPUT Standby 9.5kVA 11.5kVA
Phase Single/Two line Three/Four line

Generator
Power Factor 1.0 0.8
Voltage *230V *400V
Cover

Excitation System Self-excited

Pole 2
Drive System Directly coupled to engine
Voltages Regulation 1.5%( Rated Speed)
MODEL KG690
Rated output 12.0kW/3000rpm, 14.0kW/3600rpm
Lift hook

Type Air-forced four-stroke OHV gasoline Engine

Cylinder Volume 688cc
Engine

No. of Cylinder 2
Muffler

Starting System Electric (recoil)

Fuel Consumption 370g /kWh
Fuel Tank Capacity 26L
Noise Lever (7m/dB) 72dB/50Hz, 78dB/60Hz
Net weight (with wheels) 152(159) kg
Hour meter
Voltmeter

Fre. meter
Ammeter
Engine switch

Output terminals
Main switch
Single-phase receptacle

Net Dimensions
910 600 620 mm
(with wheels)
(910 785 710mm)
length width height

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 2. PREPARATORY STEPS FOR OPERATION 3. SAFETY PRECATIONS FOR SERVICING

1) Environmental Requirements A). Only qualified persons should test, maintain., and repair this unit.

1-1) Outdoor use B). Always wear a face shield, rubber gloves and protective clothing
A) Install your unit in a dry and dustless place. when working on the unit.
B) Avoid the direct sunshine. Place your unit in shade. C). Do not touch the generator unit or any part of load with your bare
C) Keep your unit on a lever ground so that the unit will not move by itself . For
hands or wet hands
safely, Fix the unit on the ground by pegging.
D). Keep hands, hair, loose clothing, and tools away from moving pars
1-2) Indoor use
such as fans, belts and rotors.
A) Use in well-ventilated areas, or vent exhaust outside and away from any
building air intakes. A large volume of air is required for the operation. E). Do not breathe exhaust fumes.
B) Keep the air inlet /outlet and the exhaust gas outlet 1.5m away from any D). Stop engine and let it cool off before checking or adding fuel.
obstacle.
G). Do not add fuel while smoking or unit is near any sparks or open
C) Use under 40 degrees temperature.
D) Install your unit on a level surface.
flames.
H). Observe correct polarity ( & ) on batteries.
2) Preparation for the engine I). Do not tip battery.
A) Check level of fuel gasoline, Lubrication oil. Add any of those fluids if is below J). Use equipment of adequate capacity to lift and support unit and
the sufficient level specified in the Engine Owner's Manual.
components.
B) Check all major bolts and nuts on the engine. Tighten any loose bolts and nuts.

3) Electrical connection with load

A) Make sure that the load does not exceed the power capacity of your unit.
Connect electrical connections properly.

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 4. WARM-UP PROCEDURE 5. STARTING-UP PROCEDURE

A) Check all fluids daily. (The unit is shipped without lubricating oil.) A) Return speed control level to left position.
B) Turn the fuel cock to ON position. B) Ensure voltmeter indicates normal.
C) Set the main switch to OFF. C) Set the main switch to ON.
D) Pull out the Chock lever. D) Observe the voltage is in the normal loaded range.
E) Turn the engine start key to START position.
F) Warm-up time is about 3-5 minutes.

6. STOP PROCEDURE

A). Set the main switch to OFF.

B). Turn the engine start key to STOP position.
C). Close the fuel cock if the unit is in storage or transportation.

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 7. SIMPLIFIED TROUBLESHOOTING GUIDE 8. MALFUNCTION AND COUNTERMEASURES

This guide is intended to give brief information for troubleshooting with

Complaint Possible cause Remedy
no testing or measuring instruments to check the unit.
1. Speed up engine until rated
However, testing and measuring instruments are required to diagnose 1. Engine speed too low
voltage is reached.
parts and components in many trouble cases. 2. Rotor diode breakage
2. Replace diode
No power or 3. Rotor wiring breakage
If you cannot determine the cause by visual inspection, you should 3. Repair or replace
Insufficient power 4. Rotor wiring breakage
4. Repair or replace
consult your dealer whom you purchased this unit from. 5. Main switch breakage
5. Replace switch
6. AVR failure
6. Replace VAR

1. Engine speed too low 1. Speed up engine until rated

2. Too long a line is used voltage is reached.
Power is available between generator and 2. Relocate the unit as close
but falls upon load as possible to the load
loading 3. The load is too large. 3. Reduce the load to and below
the capacity limit of the unit.

Loading trips 1. Overloading 1. Reduce the load

off the main 2. Fault on the load side 2. Check to locate the faulted
switch instantly circuit, and repair it.

Noise from bearing Bearing worn out Replace bearing

Voltmeter doesn't function Voltmeter failure Replace Voltmeter

Ammeter doesn't function Ammeter failure Replace Ammeter

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 9. ELECTRICAL SKELETON DIAGRAM

KGE12E3 ELECTRICAL SKELETON DIAGRAM

KGE12E ELECTRICAL SKELETON DIAGRAM

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 2. Modified coefficient table of ambient condition power
10. APPENDIX
The conditions of generator rated output:
Altitude: 0 m Ambient temperature: 25 Relative humidity: 30%
1. The choice of the electric cable
The choice of the electric cable depends on the allowable current of the cable Ambient modified coefficient: C (Relative humidity 30%)
and the distance between the load and the generator. And the cable section
should be big enough. Ambient temperature ( )
If the current in the cable is bigger than the allowable current, it will become over Altitude
(m)
hot and the cable will be burnt. If the cable is long and thin, the input voltage of 25 30 35 40 45
the electric appliance will be not enough, causing that the generator doesn't start.
In the following formula, you can calculate the value of the potential "e". 0 1 0.98 0.96 0.93 0.90

1 Length 500 0.93 0.91 0.89 0.87 0.84

Potential (v) = Current (A) 3
58 Section area
1000 0.87 0.85 0.82 0.80 0.78
The relations among of the allowable current, and length, section of the Insulating
cable (single core, multi-core) are as follow:
2000 0.75 0.73 0.71 0.69 0.66
(Presume that the use voltage is 220V and the potential is below 10V.
3000 0.64 0.62 0.6 0.58 0.56
The application of the single-core insulating cable section mm2
Length 4000 0.54 0.52 0.5 0.48 0.46
beneath 50m 75m 100m 125 150 200
Current
Note: When the relative humidity is 60%, the modified coefficient is C-0.01
50A 8 14 22 22 30 38
When the relative humidity is 80%, the modified coefficient is C-0.02
100A 22 30 38 50 50 60
200A 60 60 60 80 100 125 When the relative humidity is 90%, the modified coefficient is C-0.03

300A 100 100 100 125 150 200 When the relative humidity is 100%, the modified coefficient is C-0.04

The application of the multi-core insulating cable section mm2 Counting example:
Length When the rated power of generator is PN =5KW, altitude is 1000m, ambient
beneath 50m 75m 100m 125 150 200
Current temperature is 35 , relative humidity is 80%, the rated power of generator is:
50A 14 14 22 22 30 38 P=PN (C-0.02) = 5 (0.82-0.02) = 4KW
100A 38 38 38 50 50 60
200A 38 2 38 2 38 2 50 2 50 2 50 2
300A 60 2 60 2 60 2 60 2 80 2 100 2

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