WARRIOR GENERATORS LDG12S User manual

WARRIOR GENERATORS
USER MANUAL
FOR MODELS:
LDG12S & LDG12S3

CONTENT
1. Safety Instructions 1
2.
Specifications 2
3.
Components of Generator Set
DG12 Components 3
DG12S Components 4
4.
Preparation Before Start
DG12 Check Before Operation 5
DG12S Check Before Operation 6
5.
Operation 7
6.
Stopping Generator 7
7.
Maintenance
DG12 Check and Maintenance
DG12S Check and Maintenance
9
10
8. Appendix and Suggestion 11
9. Urgent Problem Solution 12
10.
Electrical Wiring Diagram (Single phase) 13
11.
Electrical Wiring Diagram (Three phase) 13

-1-
1. Safety Instructions
Notes: Please read this manual carefully and make sure you fully understand, to
avoid serious damage to user or product.
• Careful inspection required before starting generator each time.
• In order to prevent fire disaster and keep the generator set in a well ventilation
area, please keep the generator set at least 1 metre from any objects. ENSURE
generator set is as far away as possible from flammable substances.
• Keep kids and pets far away from running generator set to prevent serious
injury.
• Make sure a clear SOP is in place and forbid any person who are not
trained in operating generator set.
• Make sure adding fuel under well ventilation condition while the generator set is
shut down and isolated. Diesel Fuel is combustible and can ignite.
• Do not overfill the fuel tank, fill to recommended level on gauge.
• Make sure the fuel cap is tightly secured.
• If any fuel spills, must clean before starting the generator and DO NOT start
generator until area is dry.
• Make sure there are no naked flames such as cigarettes, matches or flames
where the generator is being re-fueled or fuel storage.
• Diesel engines produce toxic carbon monoxide exhaust fumes, do not breath
exhaust fumes. Never operate unit indoors, enclosed areas or inadequate
ventilated areas. OUTDOOR use only.
• Operate the unit on stable ground to prevent accidents.
• The exhaust and muffler is very hot when in operation, even after use, DO NOT
touch the engine or muffler while they are still hot. Toavoid fire hazard or burns,
leave generator to completely cool down.

-2-
2. Specifications
Model
DG12(Open frame)
DG12S(Silent)
DG12
DG12-3
DG12S
DG12S-3
Engine
Engine model
290F
Type
Air cooled, 4-stroke, Twin-cylinder
Bore mm
90
Speed rpm
3000/3600
Max output hp
20
Starting system
Electric start
Generator
Type
Brush/Brushless,
AC single phase
Brush,
AC three phase
Brush/Brushless,
AC single phase
Brush,
AC three phase
Frequency Hz
50/60
Voltage V
110,115,120,
220,230,240,
110/220,115/230,
120/240
220/380
230/400
110,115,120,
220,230,240,
110/220,115/230,
120/240
220/380
230/400
Rated output KVA
10/10
12.5/12.5
10/10
12.5/12.5
Max output KVA
11/11
13.75/13.75
11/11
13.75/13.75
Power factor
1.0
0.8
1.0
0.8
Fuel tank capacity L
25
25
60
60
Duration of full h
≤5.5/5.0
≤12/11.5
Fuel consumption g/kWh
≤350
Size (LxWxH) mm
910×578×668
1160×675×945
Net weight kg
170
174
295
300

-3-
3. Generator Set Assembly Components
DG12 Components
Item
Description
Quantity
1
Top cover
1
2
Frame
1
3
Engine side cover
1
4
Front cover
1
5
Muffler assy
1
6
Air cleaner assy
1
7
Engine
1
8
Shock absorber
6
9
Lock wheel
2
10
Alternator
1
11
Wheel
2
12
Control panel
1
13
Battery
1
14
Motor side cover
1
15
Fuel tank
1
16
Back cover
1

-4-
DG12S Components
Item
Description
Quantity
1
Control gate
1
2
Control panel
1
3
Battery boards
1
4
Front cover
1
5
Left door
1
6
Upper plate
1
7
Rubbe rcover
1
8
Alternator clapboard
1
9
Alternator
1
10
Muffler heat
insulation cover
1
11
Muffler assyⅠ
1
12
Engine
1
Item
Description
Quantity
13
Muffler assyⅡ
1
14
Shock absorber
6
15
Battery
1
16
Inner cover
1
17
Air cover
1
18
Back cover
1
19
Bottom seat
1
20
Fuel tank
1
21
Wheel
2
22
Lock wheel
2
23
Door lock cover
2
24
Right door
1

-5-
4. Inspection Before Operation DG12 Check Before Operation
1. Oil level
Notice: Check oil level before operation each
time.
① Opening lock button, and then raise upper
cover.
② Loosen oil dipstick, clean it with cloth,
and then insert into filter neck (do not
screw). Add engine oil level if it below the
lower limit (includes lower limit) when take
out, the ways of adding oil as below.(7.1. ①), Finally,
install and plug oil gauge.
Notice: DO NOT run generator with low oil level
or below Minimum, this will cause generator engine
parts to damage.
③ Check any damage of the battery, if damaged, please
replace battery.
2. Fuel level
① Open the generator cover,
unscrew the fuel tank cap.
② Check fuel level, if it is very
low, add the fuel.
③ Filling the fuel to the
fuel filter shoulder.
④Screw the fuel tank cap well,
fit the generator cover.
UPPER LIMIT
LOWERLIMIT

-6-
DG12S Check Before Operation
1. Oil level
Notice: Check oil level before operation each time.
① Open right door , Y ou will see the oil dip stick.
② Loosen oil dipstick, remove clean it with cloth, and
then insert into filter neck (do not screw). Add
engine oil if it is below the minimum level, ways of
adding oil as below in (7.1.①), Finally, install and
plug oil cap.
Notice: DO NOT run generator with low oil level
or below Minimum, this will cause
generator engine parts to damage.
2. Fuel level
Caution: Please refuel in a well ventilated area,
make sure there is NO cigarettes, naked
flames or sparks when refuel.
① Open left door , check the fuel level indicator .
If fuel level is low, unscrew the tank cap, fill the fuel though fuel filter. After filing
fuel, screw back the tank cap.
②If generator won't operate for a period time, drain remaining fuel through the
discharge hole in the bottom of fuel tank (located in the bottom of generator
below panel).
③ Check any damage of the battery, if damaged, please replace battery.
OPEN
UPPER LIMIT
LOWER LIMIT
Fuelvolume
indicator
Fuel tank
cap
Battery
boards
Battery

-7-
5. Operation
Single Phase Control Panel
Three Phase Control Panel
Starter switch AC circuit breaker Starter switch AC circuit breaker
(1) Checking before operation
Turn the AC circuit breaker switch to “OFF” position, To protect your personal
security, make sure the generator is grounded recommended 200mm earth rod.
BREAKER
ON
(2) Starting
generator OFF
STARTER SW
Electric starting
Turn the starting key at “start” position (no more than 8
seconds), remove your hand from the key as soon as the engine
starts and let the key return automatically to initial position. If the
starting motor doesn't start, please wait for about 30 seconds
OFF ON
before attempting to start again.
(3) AC application
①In accordance with the actual situation to connect the load
through the load terminals or wiring socket.
② Connect AC circuit breaker , the genset begin to offer power .
6. Stopping Generator
Caution: DO NOT stop the generator when it's loaded. it will
damage the generator.
START
BREAKER
ON
OFF
①Turn off AC breaker
Turn the breaker switch to “OFF” position.
②Turn off starter switch
Turn the key to “OFF” position.
STARTER SW
AC output Ground pole AC output
OF F ON O IL AL E RT P O WE R V OL T ME TE R
BR EA K ER
0 15 0 300 450
V
S TAR T
S TAR T ER S W.
U V W N
OI L A LE R T P O W E R V O LT ME TE R
BR EA K ER
OF F O N
S TAR T
S TAR T ER S W.
AC output Ground pole AC output
0 1 00 20 0 300
V
BREAKER
ON
OFF
OFF ON
START

-8-
20w 40
10w 40
7. Maintenance and Remedy of Generator Set
Notice: Proper maintenance is not only the basis of safe, economical and easy
way of generator operation, but also helpful to reduce the air pollution.
Warning: If the maintenance instructions are not followed properly, it may cause
serious personal injury.
Maintenance Schedule
Maintain period
Item month
working hours
Every
time use
The first
month or
20 hours
Every three
months or
100 hours
Every three
months or
100 hours
Oil
Check
Renew
(First time)
(Second time)
Air cleaner
element
Check
Clean
The valve gap
Check-
adjust
The liquid of
the battery
Check
Oil filter
Clean
Renew
Fuel filter
Renew
Fuel pipe
Check
Every two years or necessary to renew
Recommend oil
4 stroke diesel engine oil, API CE, CF
the same as the CG (SAE10W-30) oil.
S A E
10w
20w
20
30
40
-30 -20 -10 0 10 20 30 40 (C
A.P.I diesel engine maintenance classification 0 20 40 60 80 100(F
Oil should be CE or over CE standard Recommend number
Can use range

-9-
DG12 Maintenance
1. Change the oil
① Please prepare the oil container under the drain plug , use the fork to release
the drain plug, then begin to pull out the oil, when the oil pull over, if necessary,
use the diesel to clean the inside of the cylinder block. In the end lock the drain
plug back.
② Open the lock, over the front cover (4.1.①), screw the cylinder head oil cap (2)
as the photo, pull the oil until reach the oil gauge max limited (4.1.②), in the
end screw back the cylinder head stud.
2. Air cleaner
① Remove the side plate of the engine, release the clip, unload the lower half part
of the air cleaner, and take out the filter element in the middle; wash the filter
element with diesel fuel and put it back in the air cleaner after it is dry.
Oil cap
Drain plug
Clip

-10-
DG12S Maintenance
1. Change the oil
① Open left door, use the fork to release the drain plug (don't take out screw), put
the oil guide groove under the drain plug, let its outlet connect with oil
container, then completely remove the oil drain plug. Begin to release out the
oil and when the oil sump is empty, if necessary, use the diesel to clean the
inside of the cylinder block. Replace drain plug back.
② Move the plastic rounded lid on the top of genset, unscrew the cylinder head oil
cap, fill the oil until reach the oil gauge max limited (4.1. ②), in the end screw
back the cylinder head stud.
2. Air cleaner
① Move the upper plate and back cover of the generator, you will see the air
cleaner. release the clip, unload the lower half part of the air cleaner, and take
out the filter element in the middle; wash the filter element with diesel fuel and
put it back in the air cleaner after it is dry.
Oil cap
Plastic rounded lid
Drain plug
Oil guide
groove
Oil container
Clip

-11-
8. Appendix and Suggestions
1. Storage
It is necessary to store the generator in correct way to keep generator in good
condition. Following steps are to protect the generator from rust and corrosion
which would damage its performance and appearance.
① Cleaning
If the generator has just run over, clean it after cooling at least 2 hours. Then
clean the surface of generators, paint the damage part, and coat with a thin
layer of film.
② Fuel
Diesel fuel deteriorates during storage, which will make the starting of the
generator more difficult and produce glue materials that would clog the fuel
system. It is necessary to clean or replace the fuel system if diesel fuel
deteriorates during storage.
2. Storage instructions
① Do not touch the muffler. Around the exhaust port of the muffler is very hot
while generator is running and the heat will remain for some time after
generator stops. To prevent burn or fire, do not move the generator into the
storage room until it is cooled.
② Storage room should be of good ventilation and far from fire place like stove,
water heater, dryer, etc, in order to avoid possible serious injury and damage to
equipment. Storage room should not be in the wet areas which would cause the
generator rust and corrosion.
③Put the generator on a level surface as tilting may cause fuel or oil leaks.
3. Transport
①If the generator has just run over, please do the shipment after cooling two hours
because the exhausting system is still very hot which may burn you or cause a
fire.
②Put the generator on a level surface while shipping to prevent leaking the oil.

-12-
9. Methods of Unexpected Problem
Generator can't start
Cause
Remedy
Check the power
control system
Bad connections of
current line
Check each connector
Battery power is low
1. Charge the battery
2. Change the battery
Check fuel and
machine oil
Without fuel
Add fuel
Without oil
Add oil
Fuel deterioration or
contain deteriorated fuel
Drain the fuel tank and
add fresh fuel
Check cylinder
compression
Piston ring worn or rings
in wrong place
Change and adjust
piston ring
Valve clearance is not
correct
Adjust the clearance as
per operational manual
Bolts of cylinder head
are not tight
Re-tight the bolt
Check fuel supply
system
Fuel oil or switch of fuel
oil plugs
Replace or repair
defective parts
No voltage output
Possible cause
Remedy
Check AC circuit
breaker
AC circuit breaker is
not open
Turn the AC circuit
breaker to “ON” position
AC circuit breaker
is broken
Replace the AC
circuit breaker
Check AVR
AVR is broken
Replace AVR
Send generator to
repair center
Motor failure, circuit
failure
Replace or repair
defective parts

-13-
10. Electrical Wiring Diagram (Single Phase Generator)
11. Electrical Wiring Diagram (Three Phase Generator)