WARRIOR DG6700 User manual

DG6700
DIESEL GENERATOR
OWNERS MANUAL
BEFORE OPERATING THIS EQUIPMENT
PLEASE READ THESE INSTRUCTIONS CAREFULLY

3
Preface
Thank-you for purchasing this tĂƌƌŝŽƌgenerator.
This operation manual contains information on how to operate and service your generator
correctly. Please read this manual thoroughly before using your tĂƌƌŝŽƌ generator to
ensure the proper operation. By following these instructions carefully, the best working
condition of this generator is maintained therefore extending the life of this machine. If you
have any problems or queries, please do not hesitate to get in touch.
The information contained in this manual is correct at the time of printing, however this
information may vary with development of the product in the future.
To ensure correct and safe running of this machine, please take careful note of all safety
warnings and cautions.
The 'Warning' label indicates that failure to follow these warnings properly can result in
property damage, serious injury or death. Read all labels and this user's manual before
operating this generator. Only operate this machine is well ventilated areas. Exhaust gas
contains poisonous carbon monoxide which can be deadly. Always stop the engine before
refuelling and then wait 5 minutes before re-starting the machine. Check for spilt fuel or
leaks and clean and/or repair these before use. Keep any sources of ignition away from the
fuel tank at all times.
The 'Caution' label indicates that severe personal injury or equipment damage may occur if
instructions are not followed carefully.
This tĂƌƌŝŽƌ generator will meet your requirements if you operate it properly according to
this manual. If the instructions in this manual are not followed carefully personal injury,
equipment damage or death may occur. For this reason, it is very important to read and
understand all information contained in this manual before operating your tĂƌƌŝŽƌ
generator.

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1. To prevent fire
Never add fuel to the fuel tank whilst the engine is running. Wipe away any spilt fuel
or oil with a clean cloth before operating. Keep explosives and any other flammable
products away from the machine at all times.
-To prevent fire and to provide adequate ventilation, keep the generator at least
one metre away from buildings and other equipment during operation.
- Operate the generator on level ground.
- Do not place the generator indoors whilst the engine is still hot.
2. To prevent inhaling exhaust fumes
Exhaust gas contains poisonous carbon monoxide which is harmful to health and can
kill. For this reason, never use the generator in a closed area or areas with poor
ventilation.
3. To prevent burns
The muffler and the engine body becomes very hot whilst the engine is running or
just after running. To prevent any burns, do not touch these parts during these
times.
4. Electric Shocks, Short Circuits
To avoid electric shocks or short circuits, do not touch the generator if your hands
are wet. This generator is not waterproof and should not be used in an area which is
exposed to rain, snow or water sprays. The use of this generator in a wet place can
cause short circuits and electric shocks during operation.
- The generator should be grounded to prevent electric shocks from faulty
appliances. Connect a length of heavy cable between the generator's ground
terminal and the and an external ground source.
- Do not connect tools or other appliances to the generator before it has been
started. If equipment is connected starting the generator may cause sudden
movements of the equipment, resulting in accidents or injuries. It may also damage
the alternator.

5
- Most electric motors require up to 3 times the rated wattage to start
- Do not exceed the specified current limit of any socket.
- Do not connect the generator to a household circuit of a house or building unless it is
through a mains/generator changeover switch

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Contents
1. Main Technical Specifications and Data.............................................................
6
2. Configuration......................................................................................................
6
3. Preparation for Starting ...................................................................................
7
4. Starting the Generator.......................................................................................
10
5. Operating the Generator....................................................................................
11
6. Load.....................................................................................................................
12
7. Stopping the Generator......................................................................................
13
8. Periodic Checks and Service................................................................................
14
9. Long-term Storage..............................................................................................
17
10. Troubleshooting and Remedy...........................................................................
18
11. Wiring Diagram.................................................................................................
19
12. Service Record...................................................................................................
21
13. Notes.................................................................................................................
22
14. Declaration of Conformity.................................................................................
23

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1. MAIN TECHNICAL SPECIFICATIONS AND DATA
Model
D'ϲϳϬϬϬ
Generator 
Rated Frequency (Hz)
50
Max. Power (KW/kVA)
5/6.ϯ
Voltage (AC) (V)
1džϭϭϬǀϭϲĂŵƉΘϭdžϭϭϬǀϯϮĂŵƉϮϰϬǀϯϮĂŵƉ
WŚĂƐĞ ^ŝŶŐůĞ
Engine speed (r/min) 3ϲ00
ŝƐƉůĂĐĞŵĞŶƚ ϰϭϴ
^ƚĂƌƚ^LJƐƚĞŵ ůĞĐƚƌŝĐ<ĞLJ^ƚĂƌƚ
DC Output
12v
Run time
хϭϮ hourΛϭϰůŽĂĚ
EŽŝƐĞ>ĞǀĞů ϲϵĚĂΛϳŵ
Engine Model
ϭϴϲ&
EĞƚƚWeight (kg) 1Ϯϴ
Dimensions (LxWxH) (mm)
910 x 5ϯϬ x 7ϰ0
2. CONFIGURATION
2.1 Parts Names

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3. PREPERATION FOR STARTING
3.1 Selection and Handling of the fuel
Selection of fuel
Only use standard specification diesel, this can be red or white
Keep dust and water out of the fuel
When filling the fuel tank from drums, make sure that no dust or water is mixed in
with the fuel. This can cause serious damage to the fuel injection pump or the
injector nozzle.
Do not overfill
Overfilling can potentially be very dangerous. Always leave a 25mm gap above the
fuel level.
- Refuel in a well ventilated area with the engine stopped.
- Do not smoke or allow flames or sparks in the area where the engine is refuelled or where
the fuel is stored.
- Do not overfill the diesel tank and make sure the filler cap is securely closed after
refuelling.
- Take care not to spill fuel when refuelling. If any fuel is spilled, make sure the area is clean
and dry before starting the engine.
3.2 Check and Refill the Engine Oil
- Always check the engine oil level with the generator on a flat, level surface before starting
or refilling the machine.
- If an insufficient amount of engine oil is used, damage to the engine may result. It is also
dangerous to overfill the engine with oil, as in extreme cases, the piston oil control ring
cannot cope with the excess oil and the engine oil that passes to the combustion chamber
above the piston rings can combust and the engine may over-rev highly with no throttle
control, causing severe damage.
This generator is equipped with a low oil pressure warning system. This system will stop the
engine automatically when the oil pressure falls below the minimum pressure required. This

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helps prevents damage such as bearing seizures etc. However, this should not be relied
upon and the engine oil level should be checked and topped up if required, daily.
To ensure the generator maintains a top quality performance and the life of the generator is
as long as possible, it is important to use the correct engine oil - SAE15w40 diesel engine oil
and change after the first 20 hours, then every 100 hours.
If the correct engine oil is not used, or the engine oil is not replaced every 100 hours, as
required, the risk of crankshaft bearing failure, piston seizure, piston ring sticking and
accelerated wear of the cylinder liner, main bearing and failure of other moving
components increases significantly. This means that the generator life will be shortened.
3.3 Service the air cleaner
1. Remove the air cleaner inspection cover.
2. Screw off the wing nut and remove the air cleaner cover and take out the element.
- Do not wash the element with detergent.
- Replace the element if the engine output decreases or a excessive exhaust smoke is
noticed.
- Never run the generator without the element, otherwise rapid engine wear will
result.
3. Reattach the air cleaner cover and screw on the wing nut.

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3.4 Checking the Generator before start up.
1. Turn off the main breaker switch and remove all loads.
Be sure to turn off the main breaker switch before starting. The generator should be
earthed to prevent electric shocks.
- Before starting the engine, be sure to switch OFF any appliances connected to it.
- Ensure that the breaker switch is OFF before switching between 115v/230v.
3.5 How to open the cabinet door and covers of this tĂƌƌŝŽƌgenerator
1. Open the cabinet door for daily inspection. Turn the lever counter clockwise and
raise the door.
2. Loosen the bolt of the air cleaner cover to check the air cleaner.
3.6 Break-in Period Operation
The first 20 hours are the break-in period of the engine. For this reason, it is important to
follow the following instructions during this period.
Warm up the engine 5 minutes after the initial starting, before applying load.
Avoid applying loads above 3kw during the first 20 hours of operation.
It is important to replace the engine oil on time. Replace the engine oil whilst the
engine is warm, after 20-hours running. Ensure that old engine oil is drained out
completely.

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4. STARTING THE GENERATOR
Do not connect tools or any other appliances to the generator before starting.
1. Starting
1. Open the fuel cock.
2. Set the engine speed lever to the 'RUN' position.
3. Turn the starting key clockwise to the 'START' position. Remove your hand
from the key as soon as the engine starts. If the engine does not start after 10
seconds, wait 15 seconds before trying again. If it does not start after 3
attempts, check that the fuel system is fully primed.
- Running the starter motor for a long time will cause the battery to go flat and may damage
the starter motor.

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- Always leave the starting key in the 'ON' position while the engine is running.
2. Battery
1. When you first install the battery, ensure that the battery's polarity is the same
as the generator's battery leads - Black = negative, Red = positive. Check the
voltage is 12.3V+, if lower, the battery must be charged.
2. Check that the voltage is correct every month. The battery should be between
12.5v and 13.6v. When the engine is running it should re-charge the battery.
3. If the battery voltage is too low, it will require charging before use.
4. Keep the battery in a cool, dry place. It is important to clean the battery every
three months and charge every six months.
5. OPERATING THE GENERATOR
1. Warm up the engine without load for around three minutes.
2. Check that the oil alarm lamp is lit. This ensures that the low oil warning system is
working.
- This generator features a low oil pressure warning system. This is activated by low oil
pressure or engine oil shortage. In these cases the engine will stop automatically. The
machine will not restart without refilling the engine oil. Check the oil level and refill.

13
- Do not loosen or readjust either the engine speed limiting bolt or the fuel injection limiting
bolt as this will cause the performance of the generator to be affected.
5.2 Checks during the running of the generator
1. Check that there is no abnormal sound or vibration.
2. Check that the engine is running smoothly without mis-fire.
3. Check the colour of the exhaust- Is it too black or white?
4. Check that there are no oil or fuel leaks.
If you notice any of the above, stop the engine and find the fault. Please contact Genpower
for assistance if required.
- If the engine has been running, the muffler will become very hot. Be careful not to touch
the muffler until it has had time to fully cool down.
- Never refuel the fuel tank whilst the engine is still running.
6. LOAD
- Do not start 2 or more appliances simultaneously- start them one by one.
- Do not use floodlights together with other appliances
6.1 230v AC Use
1. After switching ON the main breaker switch, check the voltmeter reading. The
voltmeter should point to 230v ± 5% (50Hz) for single-phase and 400v ± 5% for three
phase generators, the load can now be applied.
Connect the equipment to the generator in correct order. Connect the loads with the largest
motor first, then the smaller items. If the generator is overloaded the main breaker will trip.
- Reset the breaker trip switch and reduce the electrical load on the circuit. Wait a few
minutes before resuming operation.
6.2 12v DC Use
1. DC terminals are only for charging 12V batteries.
2. Set the main AC breaker switch to the 'OFF' position whilst charging.

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- Connect the positive and negative charging lead clips to the correct poles of the battery.
- If you try to charge a large capacity battery, which is at a low voltage, excessive current
flow may occur. This may result in the fuse for the 12v DC blowing.
- Do not use 12V DC and 230V AC at the same time.
Battery Charging
- Battery vents contain explosive gas. For this reason, keep sparks, flames and cigarettes
away from the battery. To prevent from creating a spark near the battery always connect
the charging cables to the battery first and only then to the generator. When disconnecting,
you should disconnect the cables at the generator first.
- Charge the battery in a well ventilated area.
- Before charging, remove the cap from each cell of the battery and ensure the electolyte
level is correct.
- Stop charging if the electrolyte temperature exceeds 45⁰C.
6.3 Electrical appliances, particularly motor driven equipment, will have a very high start-
up current. The table below provides reference for connecting these appliances to the
generator.
Type
Wattage
Typical
Appliance
Example
Starting
Rated
Appliance
Starting
Rated
Lighting
X1
X1
Incandescent
lamp or
heating
appliance
Incandescent
lamp 1000w
100VA
(w)
100VA
(w)
Heating
appliance
Fluorescent
lamp
X2
X1-1.5
Fluorescent
lamp
Fluorescent
lamp
80VA (w)
40 -60VA
(w)
Motor
Driven
Equipment
X3-5
X1-2
Refrigerator
or electric
fan
Refrigerator
150w
450-
750VA
(w)
150-
300VA
(w)
7. STOPPING THE GENERATOR
1. Disconnect the load from the generator.
2. Turn off the main breaker switch.

15
3. Run the generator without load for three minutes. Do not stop the engine suddenly
or whilst under load. This can damage the AVR and cause damage to the alternator
through overheating.
- Turn the electric key start switch to the 'OFF' position, or Press down the stop lever.
- Turn the fuel cock lever to the 'S' position
- Do not stop the engine with the decompression lever.
- Do not stop the generator when under load. Serious damage to the alternator and the AVR
may occur.
8. PERIODIC CHECKS AND SERVICE
Periodic checks and service are extremely important for keeping the engine in good
condition and durable. The chart below indicates what checks to make and when to make
them.
- Ensure the engine is off before performing any service. If the engine must be run, make
sure that the area is well ventilated. The exhaust contains poisonous carbon monoxide gas.

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Item
Every
Day
First
Month
or 20
hours
Three
Months
or 100
hours
Six Months
or 500 hours
Every
Year or
1000
hours
Check and refill with diesel
Yes
Change engine oil
Yes
Yes
Check and refill engine oil
Yes
Check for oil leakage
Yes
Check and tighten fastening parts
Yes
Yes
Replace engine oil
Yes -
first
time
Yes
Clean engine oil filter
Yes
Yes
Replace engine oil filter
Yes
Replace air cleaner element
(Service more frequently
when used in dusty areas)
Yes
Replace fuel filter
Yes
Check fuel injection pump
Yes
Check injector nozzle
Yes
Check fuel pipes
Yes- Replace
if necessary
Adjust clearance of intake/exhaust
valves
Yes-
First
Time
Yes
Grind intake/exhaust valves
Yes
Replace piston rings
Yes
Check battery condition
Yes
Check carbon brushes and slip rings
Yes
If you need technical advice, please contact us for assistance.
8.1 Replace engine oil
Remove the oil filler cap. Remove the drain plug and drain the old oil while the engine is still
warm. The plug is located on the bottom of the cylinder block. After draining, re-tighten the
drain plug and refill with the recommended oil.
8.2 Engine oil filter
Clean
Every 100 hours
Replace
Every 500 hours
8.3 Replace the air cleaner element
Do not clean the air cleaner element with detergent.
Replace
Every 6 months or 500 hours or sooner in
dusty conditions

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- Never run the engine without the air filter element or with a damaged element.
8.4 Clean and replace fuel filter
The fuel filter should be replaced regularly to ensure maximum engine output.
Replace
Every 6 months or 500 hours or sooner if
contaminated with dirt or water
1. Drain out the fuel from the fuel tank.
2. Replace filter.
8.5 Tighten cylinder head bolt
Tightening the cylinder head bolt requires special tools. Contact us for assistance.
8.6 Engine maintenance
1. Adjust the clearance of the intake/exhaust valves.
2. Grind the intake/exhaust valves.
3. Replace the piston rings.
4. Check injector nozzle.
All of these operations require special tools, contact us for assistance.
- Do not perform the injection nozzle test near an open fire or any other kind of fire. The fuel
spray may ignite. Do not expose bare skin to the fuel spray, the fuel may penetrate the skin and
cause severe injury or death. Always keep your body away from the nozzle.
8.7 Check and charge the battery
1. When you first install the battery, ensure that the battery's polarity is the same
as the generator's positive and negative leads (Red to positive, black to

18
negative). Check the voltage is above 12.3V, if not the battery should be
charged.
2. Check the voltage, once a month. The voltage of a standard battery is 12.5v-
13.6v.
3. If the battery voltage is too low, it should be removed and re-charged.
4. Keep the battery in a cool, dry place. It is important to clean the battery every
three months and re-charge every 6 months.
- The battery electrolyte contains sulphuric acid. Protect your eyes, skin and clothing. In case
of contact, flush thoroughly with water and get immediate medical attention, especially if it
has made contact with your eyes.
- The battery vents can give off hydrogen gas, which can be highly explosive. Do not smoke
or allow flames or sparks near the battery, especially during charging.
8.8 Check the alternator carbon brushes and slip rings
Check the generators carbon brushes and slip rings regularly. Readjust if there is a poor
contact or the brushes are worn.
9. Long-Term Storage
If storing the generator for long periods of time, make the following operations.
1. Operate the engine for 10 minutes and then stop.
2. Stop the engine. Drain the engine oil whilst the engine is still warm and refill with
fresh oil.
3. Remove the screw plug on the cylinder head cover and fill with 2cc of engine oil,
then put the plug back in place.
4. Turn the engine for 2-3 seconds with the decompression lever set at the non-
compression position and the starting key set at the 'START' position. (Do not start
the engine.)
5. Wipe off the oil and dirt from the engine and store in a dry place.

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10. TROUBLESHOOTING AND REMEDY
Problem
Fault Cause
Remedy
The diesel engine will not
start
Insufficient fuel
Refill with fuel
Fuel tap is not at ON position
Turn it to the 'ON' position
Fuel injection pump does not
deliver the fuel or deliver
insufficient fuel
Remove the injector pump
and have tested.
The governer lever is not at
START position
Set the lever to START
position
Check the engine oil level
The specified oil level should
be to the upper level.
The injector is full of carbon
Clean the injector
The starter motor turns too
slowly
Check battery charge and
12v connections - replace
starter motor
The battery is flat
Charge it or replace it with a
new one
The generator is not
producing power
Main breaker switch has not
been turned on
Turn the main breaker
switch to the 'ON' position
Alternator brushes worn
Replace the brushes
The contact in the socket is
not good
Ensure plugs are fully
inserted into sockets
The rated speed is excessive
Adjust engine speed to
produce 52hz with no load
AVR is damaged
Replace the AVR