PREFACE. Thank you for purchasing a Kipor Generator from the Coast Distribution System.

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3 PREFACE Thank you for purchasing a Kipor Generator from the Coast Distribution System. This manual covers the operation and preventive maintenance of the KGE2400X generator. All information in this publication is based on the latest product information available at the time of printing. We reserve the right to make changes at any time without notice and without incurring any obligation. No part of this publication may be reproduced without written permission. This manual should be considered a permanent part of the generator and should remain with it if it is resold. Pay special attention to statements preceded by the following words: Failure to properly follow these precautions can result in property damage, serious injury or DEATH! Read all labels and the owner's manual before operating this generator. Generators produce carbon monoxide, a poisonous, colorless, odorless gas that can cause death or serious injury. Indoor use of a generator can kill quickly. Generators should be used outdoors only. Generators should be used outdoors only and away from garages and open windows and protected from rain and snow. Always stop engine before refueling. Wait 5 minutes before restarting. Keep any source of ignition away from the fuel tank at all times. ii

4 The portable generator is not meant to be used as a permanent back-up power system for the home. A permanently installed stationary generator is designed to be safely used for this specific purpose. Do not connect this generator directly to the home utility panel. It can only be connected to a manual style transfer switch by a qualified electrician. Use of an automatic transfer switch (ATS) will cause severe engine damage. Indicates a strong possibility of severe personal injury or death if instructions are not followed. Indicates a possibility of personal injury or equipment damage if instructions are not followed. NOTE Gives helpful information. If a problem should arise, or if you have any questions about the generator, consult an authorized dealer or service center. Our generators are designed to give safe and dependable service if operated according to the instructions. Read and understand the Owner's Manual before operating the generator. Failure to do so could result in personal injury or equipment damage. iii

5 CONTENTS 1. Safety information 1 2. Identification of components 3 3. Pre-operation check 5 4. Starting the generator 8 5. Using the generator 9 6. Stopping the generator Maintenance Storage Troubleshooting Specifications Wiring diagram Warranty 22 iv

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7 1. SAFETY INFORMATION Our generators are designed to give safe and dependable service if operated according to these instructions. Read and understand the owner's manual before operating the generator. Failure to do so could result in personal injury or equipment damage. Exhaust gas contains deadly poisonous carbon monoxide. Never run the generator in an enclosed area. Be sure to provide adequate ventilation. The muffler becomes very hot during operation and remains hot for several minutes after stopping the engine. Be careful not to touch the muffler while it is hot. Let the engine cool before storing the generator indoors. The engine exhaust system will be heated during operation and remain hot immediately after stopping the engine. To prevent scalding, pay attention to the warning marks attached to the generator. The generator must be operated outside with adequate ventilation. It cannot be operated in an enclosed compartment of any vehicle or in a garage area. 1

8 To ensure safe operation: Keep away from smoking materials, sparks and other sources of combustion when refueling the generator. Always refuel in a well-ventilated location. Gasoline is extremely flammable and explosive under certain conditions. Refuel in a well ventilated area with the engine stopped. Wipe up spilled gasoline at once. Restrict application of generator in high-hazard risk to causing fire area. Do not transport the generator in a vehicle with fuel in the tank. Connections for standby power to a building's electrical system must be made by a qualified electrician and must comply with all applicable laws and electrical codes. Improper connections can allow electrical current from the generator to back feed into the utility lines. Such back feed may electrocute utility company workers or others who contact the lines during a power outage and when utility power is restored, the generator may explode, burn, or cause fires in the building's electrical system. This generator is not designed to be connected to an automatic transfer switch (ATS). Serious damage to the engine may result. Always make a pre-operation inspection before you start the engine. Place the generator at least three feet or one meter away from buildings or other equipment during operation. Operate the generator on a level surface to prevent fuel spillage or oil starvation. Know how to stop the generator quickly and understand operation of all the controls. Never permit anyone to operate the generator without proper instructions. Keep children and pets away from the generator when it is in operation. Never operate the generator with the door open or any panels removed. Do not operate in any enclosure such as an RV compartment. Keep away from rotating parts while the generator is running. The generator is a potential source of electrical shocks when misused; do not operate with wet hands. Do not operate the generator in rain or snow or let it get wet. 2

9 2. COMPONENT IDENTIFICATION 2.1 Generator Components Fuel Gauge 6. Oil Filler Cap 2. Choke 7. Control Panel 3. Fuel Valve 8. Gasoline Tank 4. Air Cleaner 9. Spark Plug 5. Recoil Starter 10. Muffler 2.3 Control Panel 3

10 2.3 Serial Number and Bar Code Identification Serial Number and Barcode Location The engine serial number is located on the engine block immediately to the left of the oil drain plug. The generator serial number is located on the aluminum shroud surrounding the alternator. Serial numbers may be required when ordering parts. The bar code label is found in three locations: on the generator front panel, on the packing carton, and on the owner s manual inside cover. The bar code identifies the production date and is used by your dealer and the customer service center for warranty administration. Please record this information below and keep this manual in a safe place along with the bill of sale. Engine Serial Number Generator Serial Number Bar Code Number 4

11 3. PRE-OPERATION CHECKS Be sure to perform the following checks before starting the generating set. 3.1 Insure the generator is on a level surface. Check for gasoline and oil leaks and correct any problems before proceeding. 3.2 Check engine oil. Take out the oil filler cap and clean the indicator stick with a clean lint free rag. Reinsert the oil filler cap without rotating it. Remove the oil filler cap and examine the oil level. If the oil level is at or below the lower level, refill the oil to the upper limit mark. Reinsert the oil filler cap and tighten securely. Use a quality high detergent 4 cycle motor oil that meets or exceeds API service classification SF or SG. Select the proper viscosity from the chart below by determining the average temperature in your area. SAE Viscosity Grades Ambient Temperature 5

12 3.3 Check the fuel level Read the gauge or remove the fuel tank cap and visually check the level. Add fuel if level is too low. Tighten the fuel tank cap securely after filling. Use unleaded 87 octane regular gasoline. Do not use premium or high octane fuels. The engine is tuned to run on regular gasoline and engine damage and poor performance may result from using higher octane fuels. Never use an oil/gasoline mixture or dirty gasoline. Avoid getting dirt, dust or water in the fuel tank. Gasoline is extremely flammable and is explosive under certain conditions. Refuel in a well-ventilated area with the engine stopped. Do not smoke or allow flame or sparks in the area where the engine is refueled or where gasoline is stored. Do not overfill the fuel tank (there should be no fuel in the filler neck). After refueling, make sure the fuel filler cap is closed properly and securely. Be careful not to spill fuel when refueling. Spilled fuel or fuel vapor may ignite. If any fuel is spilled, make sure the area is dry before starting the engine. Avoid repeated or prolonged contact with skin or breathing of vapors. KEEP OUT OF REACH OF CHILDREN. GASOLINES CONTAINING ALTERNATE FUELS If you decide to use a gasoline containing ethanol, be sure its octane rating is no lower than the specification. Do not use a blend that contains more than 15% ethanol. Do not use gasoline containing methanol. 6

13 3.4 Check the air cleaner (1) Unfasten the clips and remove the air filter cover. Remove the air filter element and observe for cleanliness. (2) Clean the air filter element by washing in soap and water or solvent. Squeeze dry and then soak in clean engine oil. Squeeze out all excess oil and reinstall. (3) Replace the element if brittle or torn. 3.5 High altitude operation At high altitude, the standard carburetor air-fuel mixture will be excessively rich. Performance will decrease, and fuel consumption will increase. High altitude performance can be improved by installing a smaller diameter main jet in the carburetor. If you continuously operate the generator at altitudes higher than 5000 feet or 1500 meters above sea level, have your authorized dealer install the high altitude main kit. No other adjustments to the carburetor are necessary Even with suitable carburetor re-jetting, engine horsepower will decrease approximately 3.5% for each 1000 feet or 305 meter increase in altitude. The effect of altitude on the horsepower will be greater than this if no carburetor modification is made. For use at lower altitudes, be sure to have your dealer return your generator to the original specification. Operation of the generator at an altitude lower than the carburetor is jetted for may result in reduced performance, overheating, and serious engine damage caused by an excessively lean air/fuel mixture. 3.6 Ambient Temperature Generator output generally derates 1% for every 10 F (5.5 ) above 85 F (29 ). The normal operating range of the generator is -20 to 113 F (-29 to 45 ). Do not operate the generator when the ambient temperature is below -20 F (-29 ) Do not operate the generator when the ambient temperature is above 113 F (45 ) 7

14 4. STARTING THE GENERATOR (1) Disconnect any load from the AC receptacle and switch off the AC breaker. (2) Set the fuel oil valve to ON position. (3). Set the choke lever to CHOKE position. 4. Set the engine switch to "ON" position. ENGINE SW ON OFF 5. Pull the starting handle until you feel resistance then pull it forcefully. (6). When the engine is warm, set the choke lever to OFF position. 8

15 5. USING THE GENERATOR 5.1 In order to keep the generating set in an optimal mechanical and electrical condition please follow these instructions: (1) Secure the grounding terminal of the set to a secure ground. (2) If the generating set is to be connected with more than one load, connect the higher starting current load first. (3) Do not exceed the maximum load rating of this generator set for more than 30 continuous minutes. (4) This set is not designed to be connected directly to a residential service panel. Use a manual style transfer switch. Do not connect this generator to an automatic transfer switch (ATS). Severe engine damage will result. 5.2 Application of Electrical Loads (1) Start the generator and bring to operating temperature (2) Switch on the AC breakers and connect the load. (3) In case of an overload or appliance short circuit, the circuit breaker will close and stop the flow of current to the receptacle. Reduce load or disconnect and repair the appliance. Reset the circuit breaker. 9

16 5.3 Load Characteristics Electrical appliances such as fluorescent bulbs and motors will draw very high current while starting and a higher current while running. Use the table below to manage electrical loads. When connecting more than one appliance to the generator, connect the one with the higher current draw first. Let it come to normal operation before connecting the second appliance. WATTAGE TYPICAL TYPE MULTIPLIER APPLIANCE WATTAGE START RUN START RUN Standard Light 40W bulbs X1 X1 Standard light bulb Heaters 200W TV Fluore- scent lamps X2 X1.5 Fluorescent Lamp 40W Motor- driven equipment X3~5 X2 Refrigerator 500W Electric fan 200W 10

17 5.4 DC Charge Function The DC receptacle is to be used for charging automotive and marine batteries only. Any other use such as operating DC motors may cause irreparable alternator damage and is prohibited. 1. Connect the charging cable to the DC receptacle of the generator and then to the battery terminals. Use only the charging cable supplied with the generator. To prevent the possibility of creating sparks near the battery, connect the charging cable first to the generator then to the battery. Disconnect the cable first at the battery. Before connecting the charging cable to a battery that is installed in a vehicle, disconnect the vehicle's battery ground cable. Reconnect the vehicle's ground cable after the charging cables are removed. This procedure will prevent the possibility of a short circuit and sparks if accidental contact is made between a battery terminal and the vehicle's frame or body. Do not attempt to start an automobile engine with the generator still connected to battery. The generator may be damaged. Connect the positive battery terminal to the positive charging cord. Do not reverse the charging cables or serious damage to the generator and/or battery may occur. The battery gives off explosive gases: keep sparks, flames and cigarettes away. Provide adequate ventilation when charging. The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing and a face shield. A. If electrolyte gets on your skin, flush with water. B. If electrolytes gets in your eyes, flush with water for at least 15 minutes and call a physician. Electrolyte is poisonous. If swallowed, drink large quantities of water or milk and follow with milk of magnesia or vegetable oil and call a physician. Keep out of reach of children. The DC output is to be used to charge batteries only. Serious damage to the stator windings can occur if connected to a DC motor or transformer. 11

18 2. Start the generator. The DC receptacle may be used while AC power is in use. The DC receptacle is protected from an overload with a fuse. If the DC circuit is overloaded, the 5 amp fuse will blow and power to the DC receptacle will cease. The red light on the DC panel will illuminate. Replace the fuse with one of the same capacity. Using a higher rated fuse may cause damage to the generator alternator. 12

19 6. STOPPING THE GENERATOR 6.1 Normal Stop a. Turn off all connected loads and disconnect from the generator. Switch off the AC breaker. 6.2 Put the engine switch in the off position and turn the fuel cock to OFF. ENGINE SW ON OFF OFF 6.2 Emergency Shutdown To stop the generator in an emergency, turn the engine switch OFF. CAUTION: Continually shutting down the generator with a load applied can lead to damage of the voltage regulator. 13

20 7. MAINTENANCE Periodical inspection and maintenance are very important for keeping your generating set in good working condition. Be sure to shut down the set before performing any maintenance and put the generator on dry and level ground. Item Service Period (1) First Every 3 Every 6 Each year Each month or months or months or or 300 use 20 Hrs. 50 Hrs. 100 Hrs. Hrs. Engine oil Check Change (2) Air cleaner Check Clean (2) Fuel strainer Clean cup Spark plug Clean Adjust Valves Adjust (3) Fuel tank clean (3) Fuel hoses Check Every 2 years (Replace if necessary) (3) Note: (1) Perform at every indicated month or operating hour interval whichever occurs first. Log hours of operation. (2) Shorten maintenance intervals if the generator is operated in high ambient temperatures or dusty conditions. (2) The above-mentioned items must be performed with the assistance of a trained Kipor generator technician. Use genuine Kipor parts or the equivalent. The use of replacement parts which are not of equivalent quality may damage the generator and void the warranty. Part Description Coast Distribution Number Spark Plug Air Filter Element Fuel Strainer Spark Arrestor To locate a parts dealer in North America, visit the website 14

21 7.1 Change engine oil Oil Filler Cap Oil Drain Plug 1. Open oil filler cap. 2. Loosen the drain screw plug and drain the engine oil. 3. Reassemble the drain screw plug. 4. Refill engine oil to the upper limit level of the oil filler cap. 5. Reassemble the oil filler cap. 7.2 Air cleaner Service (1) Unfasten the clips and remove the air filter cover. Remove the air filter element and observe for cleanliness. (2) Clean the air filter element by washing in soap and water or solvent. Squeeze dry and then soak in clean engine oil. Squeeze out all excess oil and reinstall. (3) Replace the element if brittle or torn. 15

22 7.3 Spark plug Remove the spark plug wire from the plug. Remove the spark plug with the wrench provided with the generator Visually inspect the spark plug. Discard it if any portion of the porcelain insulator is chipped or cracked. Remove any carbon buildup with a wire brush. Set the proper gap using an automotive style feeler gauge by carefully bending the side of the electrode. Reinstall the plug securely in the cylinder head. Use enough force to compress the washer but take care not to over tighten. ¼ to ½ turns is sufficient. 7.4 Spark Arrestor Maintenance 1. Allow the muffler to cool completely before servicing 2. Loosen the bolt and remove clamp 3. Carefully remove the spark arrestor. A pair of pliers may be necessary but use caution so as not to crush the spark arrestor housing 4. Use a wire brush to remove carbon deposits from the spark arrestor screen 5. Replace the spark arrestor is the screen is damaged in any way 16

23 8. STORAGE 1. Open the drain screw on the carburetor and drain all gasoline from the carburetor. Be sure to carefully collect all fuel without spilling and dispose of properly. Drain Screw Drain 2. Remove the filler cap and drain screw plug and drain the engine oil. 3. Reinstall the drain screw plug and fill with fresh oil. 4. Pull the starting rope slowly until you feel resistance. 5. It is not recommended that the generator be stored with fuel in the tank. Be sure to treat your fuel supply with a suitable fuel preservative. Exercising the Generator Any small engine is very susceptible to fuel varnishing. Gasoline fuel systems have very small orifices and passageways which can easily become clogged by fuel residue. This residue may form in the fuel system in as little as 30 days. This can lead to hard starting and rough running. Fuel preservatives are readily available at leading RV and marine dealers. Regularly add a fuel preservative to the fuel supply and exercise the generator by running it at a 50% load for 60 minutes every month. This will also help remove moisture from the alternator windings. Additionally, internal engine parts are properly lubricated. 17

24 9. TROUBLESHOOTING The engine will not start: Is there fuel in the tank? Yes Is the engine switch on? Yes Is the fuel valve on? Yes Is the enough oil in the engine? No No No No Refill the fuel tank. Turn the engine switch on. Turn the fuel valve on. Add the recommended oil. Yes Is there a spark from the spark plug? No Replace the spark plug. Still no spark Take the generator to a repair center Be sure there is no spilled fuel around the spark plug. Spilled fuel may ignite. To check: 1) Remove the spark plug cap and clean any dirt from around the spark plug. 2) Remove the spark plug and install the spark plug in the plug cap. 3)Set the plug side electrode on the cylinder head to ground. 4) Crank the engine, sparks should jump across the gap. Is the fuel reaching the carburetor? If the engine still does not start, take the generator to an authorized KIPOR dealer. No Clean the fuel filter cup To check: 1) Turn off the fuel valve and loosen the drain screw. 2) Fuel should flow from the drain when the fuel valve is turned on. 18

25 Appliance does not operate: Is the circuit breaker in the ON position YES NO Place in the ON position Check the electrical appliance or equipment for any defects. NO Take the generator to an authorized dealer. YES Replace the electrical appliance or equipment Take the electrical appliance or equipment to an electrical shop for repair 19

26 10. SPECIFICATIONS Engine Generator Model KG200 Type 4-stroke, OHV Displacement cc 196 Cooling system Forced air Ignition system T.C.I Spark plug BP6ES Fuel tank gal (L) 3.2 (15) Engine oil qt (L).85 (0.8) Compression ratio 8.5:1 Frequency 60 Hz Voltage 120 Max output 2.4 KW Max current 20 A Rated output 2.2 KW Rated current 18.3 A Excitation method Self-excitation (AVR) Phase Single-phase Power factor 1 Starting system Recoil starter Total weight lbs (kg) 86 (39) Noise Level no load-full load db Run full load 8 hours Dimensions (L x W x H) in (mm) 23.2 x 16.9 x

27 11. WIRING DIAGRAM 21

28 13. Warranty Limited Warranty Kipor Power Equipment LENGTH OF WARRANTY Generators are covered by this warranty from the date of original retail purchase for a period of two years for residential use and one year for commercial applications. Units used in rental fleets or as demonstration models will be considered commercial usage. Starting batteries included with a generator are warranted for a period or one year. The warranty coverage is continual from the original date of purchase, and does not restart upon the replacement of any part or complete unit. Individual parts replaced at any point during the warranty period are only eligible for warranty coverage for the balance of the original warranty period. ELIGIBILITY To be eligible for warranty service, the product must be purchased in the United States or Canada from an authorized Coast Distribution dealer. This warranty applies to the original retail purchaser only and is not transferable. Proof of purchase is required. Goods exported from North America as well as goods sold at auction are excluded from warranty coverage. COVERAGE Parts, labor and regular shipping costs will be covered by Coast Distribution for any failure that is proven to be a failure of material or workmanship under normal use during the applicable warranty time period. It is the responsibility of the end user to return the product to the nearest authorized repair center as directed by the warranty administration center. In the event that the generator is deemed not repairable or the necessary repair would be economically unfeasible, Coast will pay for shipping of the unit from the repair center to the designated Coast facility and the shipping of a replacement unit. Coast Distribution reserves the right to repair or replace these parts at its option. Coast Distribution may request defective parts to be returned. Anything replaced under warranty becomes the property of Coast Distribution. TO OBTAIN WARRANTY SERVICE Contact any authorized dealer or contact our national customer service center at: Phone Fax kiporcare@coastdist.com If contacting us by fax or , be sure to include a description of the problem as well as all return contact info such as address, phone number, fax number, , etc. Engine serial number, bar code number and proof of purchase are required. EXCLUSIONS This warranty does not extend to parts affected or damaged by accident and/or collision, normal wear, fuel contamination or degradation, use in an application for which the product was not designed or any other misuse, neglect, incorporation or use of unsuitable attachments or parts, unauthorized alteration, or any causes other than defects in material or workmanship. This warranty does not extend to normal maintenance items such as belts, hoses, spark plugs and filters past the first scheduled replacement or service interval for these items, whichever comes first. Coast will pay for minor adjustments for a period of ninety days from the purchase date of the generator. DISCLAIMER OF CONSEQUENTIAL DAMAGE AND LIMITATION OF IMPLIED WARRANTIES Coast Distribution denies any responsibility for loss of time or use of the product, transportation, commercial loss, or any other incidental or consequential damage. Any implied warranties are limited to the duration of this written limited warranty. Some states do not allow limitations on how long an implied warranty lasts and/or do not allow the exclusion or limitation of incidental or consequential damages. Therefore, the above exclusions and limitations may not apply to you. This warranty gives you specific legal rights and you may also have other rights which vary from state to state. 22