WARRIOR GENERATORS LDG4600E User manual

LDG4600E
DIESEL GENERATOR
OWNERS MANUAL
BEFORE OPERATING THIS EQUIPMENT
PLEASE READ THESE INSTRUCTIONS CAREFULLY

This manual contains information how to maintain and how to do troubleshooting.
Keep this owner’s manual handy, so you can refer to it at any time.
This service manual describes correct method of the maintaining this equipment. As a result of
this disregard of our rules caused by person casualty and equipment damaged, our company
does not assume any responsibility.
NOTICE:
Copyright reserved, and no part of this publication may be reproduced without our
Company’s written permission.
SAFETY MESSAGES
Your safety and the safety of others are very important. We have provided important safety
mes3ges in this manual and on the generator. Please read these messages carefully.
A safety message reminds you to potential hazards that could hurt you or others. Each safety
message is preceded by a safety alert symbol and one of three words: DANGER,
WARNING, or CAUTION. These mean:
You WILL be KILLED or SERIOUSLY HURT
if you don’t follow instructions.
You CAN be KILLED or SERIOUSLY HURT
if you don’t follow instructions.
You CAN be HURT if you don’t follow instructions.
Your generator or other property could be damaged
if you don’t follow instructions.
NOTICE
DANGER
WARNING
CAUTION

1 PREFACE 1
1-1 Generator Component Identification 1
1-2 Control Panel 3
1-3 Specifications of generator 4
1-4 Specifications of engine 6
1-5 Maintenance Standard 7
2 Periodic Maintenance 9
2.1 Service Intervals 9
2.2 Routine Maintenance Procedures 10
3. Engine Disassembly and Reassembly 13
3.1 Disassembly 13
3.2 Reassembly 19
3.3 Recoil Starter Assembly 25
4. Inspection and Service 28
4.1 Cylinder Head 28
4.2 Piston and Piston Pin 30
4.3 Connecting rod 32
4.4 Crankshaft, main bearing and flywheel 33
4.5 Camshaft 34
4.6 Timing Gear 34
4.7 Crankshaft Cover 35
4.8 Cylinder Sleeve and Block 36
4.9 Lubricating System 36
4.10 Fuel System 38
4.11 Governor 39
4.12 Adjustments 40
5. Troubleshooting 42
5.1 No fuel delivery to injection pump 42
5.2 No fuel flow from drain valve 42
5.3 Low compression 42
5.4 Hard starting (fuel delivery and compression normal) 42
5.5 No start or hard start (engine cranks) 42
5.6 Engine over speed 43
5.7 Unsteady engine speed 44
5.8 Unexpected shutdown 44
6 Generator 45
6.1 Removal/Installation 45
7 Circuit diagram 51
8 Appendix 53
CONTENTS

Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.
1. PREFACE
1-1 Generator Component Identification
Open Type: D*
1
FUEL TANK
FUEL TANK CAP
CONTROL PANEL
UP COVER FRAME
DIESEL ENGINE
RECOIL STARTER
INJECTION PUMP
SPEED GOVERNOR
COCK OF OIL DRANING
OIL PUMP
BATTERY
BOTTOM FRAME
RUBBER ABSORBER
ALTERNATOR
PUSH WHEEL KIT
MUFFLER
START MOTOR
BATTERY CHARGER
OIL DIPSTICK
AIR CLEANER

Changzhou ITC Power Equipment Manufacturing Co.,Ltd.

LED4 DISPLAY

ELECTRIC START KEY
1-2 CONTROL PANEL


LEAKAGE BREAKER

PCB


GROUND TERMINAL
12V DC SOCKET
SOCKET

PRE-HEATER BUTTON

ATS SIGNAL SOCKET

12V DC FUSE


Changzhou ITC Power Equipment Manufacturing Co.,Ltd.

LDG4600E Specifications
Frequency (HZ) 50 Cooling system Forced Air cooled
Starting Watts 4600 Lubricaton system Forced lubrication
Running Watts 4200 Operation capacity (hr) >12 hrs (25% load)
Voltage (V) 1 x 110v 32 Amp / 1 x 240v
32 Amp Dimension L*W*H (mm) 720 x 492 x 650
DC output (VA) 12 / 8.3 Net Weight (kgs) 95
Pole Numbers 2Noise Level dBa@7m 84-89
Insulation BCertification ISO9001-2000, GS,
TUV & CE
Engine Model 182FE Start System Electric Key
Engine Type
Single cyinder, vertical, 4
stroke air cooled direct
injection diesel engine.
Fuel tank capacity (L) 15
Displacement (cc) 296 Lube oil capacity (L) 1.1 (SAE10x30)
Engine Speed (RPM) 3000
Low oil pressure alarm
system Included

Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.
1-5 Maintenance Standard
Parts Item Standard Service limit
Engine
Maximum Speed (No Load)
Cylinder Compression
3150~3180rpm
≥1.17Mpa(1400rpm)
--
--
Cylinder Sleeve I.D
Cylinder Head
Cover Warpage -- 0.10mm
Piston
Skirt O.D.
Piston-to-Cylinder Clearance
Piston Pin Bore I.D.
Piston Pin O.D
Piston Pin-to-Piston Pin Bore Clearance
0.015-0.05mm
18.0mm
0.002-0.014mm
0.12mm
17.954mm
0.06mm
Piston Rings
Ring Side Clearance：
Second
Ring Enc Gap:
Second
Ring Width
Second
0.015-0.045mm
--
0.2-0.4mm
0.15-0.35mm
1.5mm
2.5mm
0.15mm
--
1.0mm
1.0mm
1.37mm
2.37mm
Connecting
Rod
Small End I.D
Big End I.D
Big Oil Clearance
Big End Side Clearance
18.002mm
30.02mm
0.040-0.063mm
0.1-0.7mm
18.07mm
30.066mm
0.12mm
1.1mm
Crankshaft Crankshaft pin O.D 29.98mm 29.92mm
Valve
Valve Clearance IN
EX
Stem O.D IN
EX
Guide I.D
Stem Clearance IN
EX
Seat Width
Spring Free Length
0.15±0.02mm
0.20±0.02mm
5.48mm
5.44mm
5.50mm
0.02-0.044mm
0.06-0.087mm
0.8mm
34mm
--
--
5.318mm
5.275mm
5.572mm
0.1mm
0.12mm
2.0mm
32.5mm
7
Diesel Engine
Diesel
86.0mm
85.94mm
Ø23mm Ø23.05mm
85.80mm
86.185mm
+0.035
0
-.0002
-0.008
POWER PRODUCTS

Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.
Camshaft
Cam Height IN
Cam Height EX
Journal O.D
27.7mm
27.75mm
13.984mm
27.45mm
27.50mm
13.916mm
Crankcase
Cover Camshaft Bracket I.D 14.0mm 14.048mm
Carburetor
Main Jet
Float Height
Pilot Screw Opening
#68
13.7±1.5mm
2-1/8 turns
--
--
--
Spark Plug Gap 0.7-0.8mm --
Spark Plug
Cap Resistance 5kΩ--
Ignition Coil
Resistance Primary Coil
Secondary Coil
Air gap
0.8-1.0Ω
5.9-7.1kΩ
0.4-0.6mm
--
--
--
yGenerator
Parts Item Standard Service limit
Stator Winding Resistance Stator Winding 1.8±10%Ωat 20℃--
Stator Auxiliary Winding 3.5±10%Ωat 20℃--
Rotor Excitation
Winding Resistance Excitation Winding 51.3±10%Ωat 20℃--
Carbon Brush Carbon Brush Length 10mm 6mm
8
POWER PRODUCTS

2. Periodic Maintenance
2.1 Service Intervals
Good maintenance is essential for safe, economical, and trouble-free operation. It will also help reduce air
pollution.
Exhaust gas contains poisonous carbon monoxide. Shut off the engine before
perform any maintenance. If the engine must be run, make sure the area is well
ventilated.
Periodic maintenance and adjustment is necessary to keep the generator in good operating condition.
Perform the service and inspection at the intervals shown in the Maintenance schedule below:
Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.
WARNING
(1) Service more frequently when used in dusty areas.
(2) These items should be serviced by an authorized generator dealer.
(3) When more often use, only servicing according to above correct intervals can insure the generator set
long-term use.
9
POWER PRODUCTS

Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.
10
POWER PRODUCTS
DIPSTICK
DRAIN BOLT
2-2 Routine Maintenance Procedures
2.2.1 Oil Change
Drain the used oil while the engine is warm. Warm oil drains quickly and completely.
1. Place a suitable container below the engine to catch the used oil, and then remove
the filler cap/dipstick and the drain plug.
2. Allow the used oil to drain completely, and then reinstall the drain plug, and tighten
it securely.
3. With the engine in a level position, fill to the outer edge of the oil filler hole with the
recommended oil.
2.2.2 Oil Filter Service
Remove the bolt that secures the filter and carefully pull the assembly toward
you.
The filter may be immersed in solvent then blown dry with compressed air.
Replace the filter at the scheduled service interval or anytime the screen is
damaged or all deposits cannot be removed.

Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.
11
POWER PRODUCTS
2.2.3 Air Filter Service
Remove the air cleaner cover and inspect the filter. Clean or replace dirty filter elements.
Always replace damaged filter elements.
2.2.4 Fuel Filter Service
1. Drain out the fuel from the fuel tank. Turn the screw in the drain plug counter
clockwise until fuel flows. Use a suitable container to catch the fuel.
2. Remove the three screws securing the fuel cock assembly and remove the filter
from the housing.
FUEL TANK
DRAIN PLUG
FUELCOCK
FUELFILTER
ASSEMBLY

Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.
12
POWER PRODUCTS
2.2.5 Adjust the valve clearance
(1) The clearance must be adjusted when the engine is cold.
timiLecnanetniaMdradnatS --mm51.ecnaraelctsuahxE/ekatnI
(2) Valve timing
CDTerofeb°41nepO
Intake Close 50°after BDCCDBerofeb°45nepO
Exhaust Close 10°after TDC

Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.
13
POWER PRODUCTS
3. Engine disassembly and reassembly
3.1 Disassembly
3.1.1Fueltank
1. Release the joint between the fuel line and fuel tank.
2. Release the hose clamp of the fuel line on the pump side.
3. Remove the tank.
3.1.2 Exhaust Muffler
1. Remove the flange bolt
2. Remove the set bolt
3. Discard the muffler gasket. Do not reuse.
3.1.3Aircleaner
(1). Disassemble the air cleaner cover.
(2). Pull out the element.
(3). Disassemble the air cleaner bottom case.
3.1.4 Recoil starter unit
(do not disassemble)
3.1.5Disassemblethefancover
Unbolt and remove the fan cover.
4.1.6 Starter pulley
Unbolt and remove

Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.
14
POWER PRODUCTS
3.1.7 Air inlet pipe
3.1.8 Remove electric starter motor
3.1.9 Remove cylinder head cover
3.1.10 Valve rocker arm seat
3.1.11 Push rods
3.1.12 Fuel injector
(1) Remove the high-pressure fuel line.
(2) Remove fuel injector.
(3) Be careful not to damage the nozzle washer and spacer.

Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.
15
POWER PRODUCTS
3.1.7 Air inlet pipe
3.1.8 Remove electric starter motor
3.1.9 Remove cylinder head cover
3.1.10 Valve rocker arm seat
3.1.11 Push rods
3.1.12 Fuel injector
(1) Remove the high-pressure fuel line.
(2) Remove fuel injector.
(3) Be careful not to damage the nozzle washer and spacer.

Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.
16
POWER PRODUCTS
3.1.13 Remove the cylinder head
3.1.14 Remove the injection pump
(1) Remove the pump together with the base.
(2) Ensure the hooking part of control lever is at the meshing position before
disassembling.
(3) Pull out the flat tappet remaining inside the housing
3.1.15 Crankcase cover
(1) Remove the engine oil injection pump cover.
(2) Remove the engine oil filter cover.
(3). Remove crankcase cover.

Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.
17
POWER PRODUCTS
tfahsmaC61.1.3
(1) Remove the camshaft taking care not to damage the oil seal.
(2) Note the position of the timing mark
(3) Remove and store the intake and exhaust tappets separately.
3.1.17 Remove balance shaft
3.1.18 Piston and connecting rod assembly
(1) Dismount the forcing nut of connecting rod.
(2) Remove the big end cap of connecting rod.
(3)Turnthecrankshafttothetopofstrokeandtakeoutthepiston.
- Remove carbon from the upper inner surface of cylinder barrel before removal.
.

Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.
18
POWER PRODUCTS
3.1.19 Flywheel
(1)Loosentheflywheelnut.
(2)Removetheflywheel.
·Use flywheel extractor
·Securely thread in the extractor bolts.
3.1.20 Crankshaft
(1) Remove the flywheel key
(2) Remove the main bearing thrust plate
(3) Pull out the crankshaft taking care not to damage
the oil seal.
3.1.21 Governor
(1) Remove the governor or speed control device only if necessary.
(2) Note the position of the governor spring before removal.

Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.Changzhou ITC Power Equipment Manufacturing Co.,Ltd.
19
POWER PRODUCTS
3.2 Reassembly
Reassembly procedures
·Thoroughly check and clean all parts.
·Apply fresh engine oil or assembly lube to all moving and rotating parts.
·Use new O rings and gaskets.
·Apply liquid sealant when no gasket is specified
·Be sure all clearances and specifications among parts are observed.
·Align matching marks while reassembling.
·Use the correct bolts, nuts and washers. Apply proper torque values when specified.
·Apply lube oil to the thread parts and flange surfaces before tightening the major
.euqrotdeificepsehtotstlob
3.2.1 Assemble governor or speed control device
·Reassemble the governor or speed control device if it has been removed.
3.2.2 Crankshaft
(1) Insert the crankshaft.
(2) Install the main bearing thrust plate.
(3)Attach the flywheel key to crankshaft.
·Be sure crankshaft is in proper position.
·Apply grease to the oil seal lips.
·Apply lube oil to the crankshaft journal and
crank pin.
3.2.3Flywheel
Tighten the flywheel nut with torque wrench
after installation.
Flywheel Nut Torque Value
130-150 N.m
3.2.4 Piston and connecting rod
(1) Move the crankshaft to the upper dead point then install the piston and
connecting rod. Align the marks on the top surface of the piston with the crankcase
cover side.
(2) Install connecting rod big end cap.
·Apply lube oil to crank pin.
·Be sure every piston ring is in the correct position.
(see 4.2.4)
·Apply lube oil to the piston outer surface and the
cylinder inner surface.
·Be sure main bearing is at proper position.
·Check whether the rod bolt retainer is at proper
position.