Whisper Power W-SC10 User Manual Download Page 10

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INFORMATION

September 2008 / W-SC6/10 for mobile applications / EN

2.4

COMPONENTS

2.4.1

Main components to identify

Fig. 3 Front View main components W-SC 6 and SC10

Fig. 4: Front view main components W-SC 6 and SC10

Fuel injection pump

Fuel injector

W-SC6

: 2x

W-SC10

: 3x

Glow plug

W-SC6

: 2x

W-SC10

: 3x

Alternator (12VDC)

Engine oil dipstick

Coolant drain plug

Oil sump hand pump

Air cleaner element

Control panel

Fuses

Digital Diesel Control

(DDC)

Identification plate

Hoist eye front

Injection pump air

bleeding screw

Engine speed adjustment

screw

Fuel solenoid

Water pump of the

alternator cooling circuit

Fuel lift pump

Engine oil filter

Alternator temperature

switch

Summary of Contents for W-SC10

Page 1: ... W SC6 SC10 3000 RPM Mobile diesel generating set 230V 50Hz Digital Diesel Control T WHISPER POWER BV Kelvinlaan 82 9207 JB Drachten The Netherlands Tel 31 512 571550 Fax 31 512 571599 www whisperpower eu V1 September 2008 Art nr 40261111 ...

Page 2: ...ol 9 2 3 3 Documentation 9 2 4 Components 10 2 4 1 Main components to identify 10 2 4 2 Generator control panel 12 2 4 3 Remote control panel 12 2 5 Technical Information 12 2 5 1 AC alternator 12 2 5 2 Engine 12 2 5 3 Digital Diesel Control system 12 2 5 4 Battery charger 12 2 5 5 Alarms and shut down 13 2 5 6 Control 13 2 5 7 Remote control 13 2 5 8 Hour counter 13 2 5 9 Load indicator 13 2 5 10...

Page 3: ...intenance 26 4 3 1 Maintenance schedule 27 4 3 2 Putting out of service 27 5 TROUBLE SHOOTING 28 5 1 Alternator electrical faults 28 5 1 1 General 28 5 1 2 Trouble shooting table alternator 28 5 2 Engine faults 29 5 2 1 General 29 5 2 2 Trouble shooting table engine 30 5 2 3 Warnings 32 5 2 4 Service address 32 5 3 Special procedures alternator 33 5 3 1 Residual voltage check excitation procedure ...

Page 4: ...or the consequences thereof WARNING A warning symbol draws attention to special warnings instructions or procedures which if not strictly observed may result in damage or destruction of equipment severe personal injury or loss of life DANGER This danger symbol refers to electric danger and draws attention to special warnings instructions or procedures which if not strictly observed may result in e...

Page 5: ... be invoiced Only after the faulty goods are returned will the invoice be credited Payment in advance may be required or guaranteed by credit card If after the faulty goods are returned it is indicated that the failure was not covered by guarantee a credit will not be issued For example if a Printed Circuit Board is returned with clear damage caused by water guarantee will be refused Freight costs...

Page 6: ... less than specified on the identification plate 3 VOLTAGE shows the nominal voltage This voltage should be within the specified tolerance at the nominal frequency 4 FREQUENCY is shown in Hz and is determined by the speed of the engine RPM 50 Hz correlates with 3000 rpm 5 CURRENT shows the maximum current that is acceptable at the specified frequency voltage and power factor 6 WEIGHT shows the net...

Page 7: ...auto start stop interval mode the generator can start unexpectedly When working on the electrical system the 3 Amp fuse must be removed from the control panel and the battery plus cable must be removed from the battery Warning signs indicate parts which could be live 2 1 3 Earth insulation failures According to local regulations and depending on the application it could be necessary to take measur...

Page 8: ... not smoke or allow sparks flames or other sources of ignition around batteries Keep a fire extinguisher on hand INCASEOFFIRE DONOTOPENSOUNDSHIELD TOAVOIDSERIOUSINJURYORDEATHFROM FIRE IMMEDIATELYDISCHARGEENTIRECONTENTSOFGASEOUS SHUTDOWNENGINES GENERATORSETSANDBLOWERS PORTABLEFIREEXTINGUISHERTHROUGHTHISPORT THROUGH HERE FIREEXTINGUISHERPORT BREAK Fig 2 Fire extinguisher port In case of fire do not ...

Page 9: ...hich is connected by close coupling to an alternator in a sound attenuated capsule The set is mounted on a steel base frame and mounted securely on anti vibration mounting pads to the capsule base All cables and hoses are guided through the capsule s sides The set is not self contained and is only operable after proper installation using additional accessories and installation materials Installati...

Page 10: ...6 2x W SC10 3x 03 Glow plug W SC6 2x W SC10 3x 04 Alternator 12VDC 05 Engine oil dipstick 06 Coolant drain plug 07 Oil sump hand pump 10 Air cleaner element 11 Control panel 12 Fuses 13 Digital Diesel Control DDC 14 Identification plate 15 Hoist eye front 16 Injection pump air bleeding screw 17 Engine speed adjustment screw 18 Fuel solenoid 19 Water pump of the alternator cooling circuit 20 Fuel l...

Page 11: ... Rocker cover 50 Hoist eye rear 51 Expansion tank 52 AC Generator 53 Exhaust 1 54 AC power output 55 Remote control 25 Dry exhaust 26 Temperature switch alternator 27 Starter motor solenoid 28 Starter motor 29 Rubber engine mounting 30 Coolant generator out 31 Coolant engine in 32 Coolant engine out 33 Battery negative 34 Fuel in Ø8mm 35 Fuel out Ø8mm 36 Battery positive 37 Coolant generator in 38...

Page 12: ... over excitation at low engine speeds and softening the effect of load switching to relieve the burden on the engine The alternator is water cooled and the cooling liquid is cooled by a radiator Further technical data on the design of the alternator can be found in drawings and diagrams in this manual 2 5 2 Engine The W SC6 generating set is based on the Mitsubishi L2E 2 cylinder diesel engine the...

Page 13: ...its can be put in parallel by using the connectors on the back of the units Refer to installation instructions 2 5 8 Hour counter The remote control offers several timer functions that helps to schedule maintenance 2 5 9 Load indicator On the remote control the load will be indicated on the display and by the LED bar The load is measured by a current transformer on the alternator 2 5 10 Fuel speci...

Page 14: ...s an open connection to drain liquid and release air 2 5 13 Technical data GENERAL Model W SC6 W SC10 RPM 3000 3000 Alternator water cooled synchronous water cooled synchronous Engine Mitsubishi diesel model L2E Mitsubishi diesel model L3E Number of cylinders 2 3 Displacement 635 cm3 952 cm3 Bore X stroke 76x70 mm 76x70 mm Combustion air consumption 0 95 m3 min 1 43 m3 min Continuous power engine ...

Page 15: ...2 DDC oil temperature switch 7 blue 1 mm2 LCP oil temperature switch 7 blue black 1 mm2 DDC exhaust temperature switch 8 blue green 1 mm2 LCP exhaust temperature switch 8 blue pink 1 mm2 DDC fuel solenoid hold 9 green 1 5 mm2 DDC fuel solenoid pull 20 pink 1 5 mm2 DDC fuel solenoid com 17 black 1 5 mm2 B terminal alternator starter motor 21 red 6 mm2 DDC R terminal alternator 18 white 1 5 mm2 DDC ...

Page 16: ...8 W SC6 10 for mobile applications EN 2 5 15 Lay outs control wiring Fig 10 Electrical Diagram control wiring W SC 6 SC10 using a 230V AC radiator fan Optional control for two speeds fans See chapter 2 5 17 ALTERNATOR TEMP SWITCH ...

Page 17: ...INFORMATION EN W SC6 10 for mobile applications September 2008 17 Fig 11 Electrical Diagram control wiring W SC 6 SC 10 using a 24V DC radiator fan ALTERNATOR TEMP SWITCH ...

Page 18: ...INFORMATION 18 September 2008 W SC6 10 for mobile applications EN Fig 12 Electrical Diagram control wiring W SC 6 SC 10 using a 12V DC radiator fan ALTERNATOR TEMP SWITCH ...

Page 19: ...INFORMATION EN W SC6 10 for mobile applications September 2008 19 2 5 16 Electrical diagrams 230 V AC 50 Hz Fig 13 Electrical diagram 230V ...

Page 20: ...mobile applications EN 2 5 17 Electrical diagrams radiator fan control Fig 15 Electrical diagram fan control using 230V AC radiator fans with two speeds fans optional Fig 14 Electrical diagram for standard fan control using 230V AC radiator fans ...

Page 21: ...INFORMATION EN W SC6 10 for mobile applications September 2008 21 Fig 16 Electrical diagram fan control using 12V or 24V DC radiator fans optional ...

Page 22: ...power So the electronic governor offers three advantages a more stable frequency and voltage and more power The electronic governor system contains two parts 1 The actuator controls the engine speed This actuator replaces the standard hold solenoid that is on all other mechanical controlled Whisper engines The actuator controls the RPM directly on the fuel rack inside the fuel pump without levers ...

Page 23: ...icted to 70 of maximum load Stopping generator 1 Switch off all electrical devices consumers If the generating set has been running under full load for a longer period do not shut it down abruptly Reduce the electrical load to about 30 of the rated load and let it run for approx 5 minutes 2 Press the STOP button 3 Switch to an other AC power source if available If a Mass Systemswitch is installed ...

Page 24: ...tarting especially electric motors and compressors from a still stand state In order to prolong the generating set s life expectancy the nominal electrical demand on the system should be about 70 or the rated generating set s maximum load Please note this when switching on your electrical devices Nevertheless the Whisper 6 10 is designed so as not to overheat even under extreme conditions Do not r...

Page 25: ...lead to cylinder glazing and high oil consumption For the same reason it is of the greatest importance to use the right oil specification The first time starting up or after running out of fuel it could be necessary to prime the fuel system 4 2 2 Bleeding fuel lines Ensure there is sufficient fuel The system is self bleeding The first time starting up or after running out of fuel it could be neces...

Page 26: ...Maximum oil level Fig 24 CHECK DAILY Level cooling liquid Hoses for loose connections or deterioration AFTER FIRST 50 HOURS Change oil and replace the oil filter Have the engine run until it is on temperature and stop it Replace the oil filter Drain oil by the sump pump into a suitable retainer and fill up with fresh oil Start the engine again and have it run for 5 minutes Stop the engine again an...

Page 27: ... runs less than 100 hours a year the oil should be changed yearly 4 3 1 Maintenance schedule Check oil level daily Check the level of the cooling liquid daily Change oil and oil filter after first 50 hours Check and tighten nuts bolts etc after first 50 hours Check exhaust after first 50 hours Check and readjust V belt after first 50 hours Check electrical connections after first 50 hours Change o...

Page 28: ...the problem is in the RPM refer to the engine fault finding paragraph Digital Diesel Control system will help to indicate failures and display causes Failure code Problem COMMUNICATION Communication error between the panel end the generator LOW START BAT Starter battery voltage too low ALTERNATOR No output battery charging voltage AC ALTERN TEMP AC alternator temperature is too high WATER TEMP Coo...

Page 29: ...ed generator peak output current This could be remedied by providing stronger capacitors to the motor or using a soft start Inquire at your nearest Whisper Power dealer or directly at the manufacturer Whisper Power in the Netherlands 5 2 ENGINE FAULTS Remove 3 Amp fuse in the control panel while working on the generator to prevent the engine from starting 5 2 1 General Most electrical problems rel...

Page 30: ...es Check fuel filter and fuel lift pump clean or replace if necessary Bleed air from fuel system refer to maintenance section Wrong valve clearance Adjust valve clearance Low compression because of dirty valves Clean valves Take off the injection bent and inspect the outlet port When little rust in the port clean the valve by taking off the valve spring and rotate until rust is removed When the ou...

Page 31: ...ture too high unsuitable fuel or water in fuel Check the fuel Check for overload Engine starts but stops after 10 up to 30 seconds Protection system stops the engine this can be caused by oil pressure failure lack of cooling water exhaust temperature alarm Overload loose wire or faulty alarm switch Digital Diesel Control will help to indicate failure Refer to paragraph 2 5 5 and 3 2 2 for informat...

Page 32: ...d Loss of compression sticking or damaged piston ring Have the compression measured Clean or replace the rings Wear out of cylinder Have the compression measured and have the engine overhauled Over temperature Overload Take away the overload Low level of coolant or air in the cooling system Fill up with coolant and release air bubbles Check if there are air blocks in the system refer to the instal...

Page 33: ...will indicate a very high resistance infinity in the reverse direction and a low resistance in the forward direction A faulty diode will give a full deflection reading in both directions with the test meter on the 10 000 ohms scale or an infinity reading in both directions Replace the diode 5 3 3 Winding resistant values If after establishing and correcting any fault on the capacitor and diode out...

Page 34: ...op dead centre T D C of compression stroke 2 The T D C of compression stroke can be found by aligning the T D C mark notch on the crankshaft pulley with the mark on the gear case ref to fig 20 3 First align the T D C mark for the No 1 cylinder Confirm that the valves do not move up or down when the crankshaft is turned about 20 degrees in normal and reverse direction of rotation If the rocker arms...

Page 35: ...enerator out of its capsule is by lifting the set with the aid of the lifting eyes 4 One can take off the complete alternator housing Before the alternator can be taken off all cables and wiring has to be taken loose first 5 The rotor can be taken off by removing the bold which goes through the shaft normal clockwise threaded The end of the shaft is specially threaded to push off the rotor from th...

Page 36: ... B same as repair kit A excluding the shaft 50201811 and O ring 50201814 50201060 Capacitor xx micro farad 2 pcs xx give value when ordering 50209132 Measuring coil 50201890 Rotary diode 50201887 Alternator bearing including O ring 50209104 Local control panel 50209200 Digital Diesel Control Unit 50212170 Fuses 10 Amps 50212154 Fuses 3 Amps 50201886 Wiring loom complete 50209102 Digital Diesel Rem...

Page 37: ...SPARE PARTS LIST EN W SC6 10 for mobile applications September 2008 37 Fig 31 Water pump type M ...

Page 38: ...MAINTENANCE LOG 38 September 2008 W SC6 10 for mobile applications EN MAINTENANCE LOG first service after 50 hours hour counter remarks next service every 150 hours hour counter ...

Page 39: ...NOTES EN W SC6 10 for mobile applications September 2008 39 NOTES ...

Page 40: ...Kelvinlaan 82 9207 JB Drachten The Netherlands Tel 31 512 571550 Fax 31 512 571599 www whisperpower eu info whisperpower nl ...

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