WARRIOR GENERATORS LDG4600E Manuel utilisateur
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
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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
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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:
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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
Table des matières
