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TROUBLE SHOOTING

January 2009 / W-SQ12 for mobile applications / EN

5 TROUBLE SHOOTING

5.1

ALTERNATOR/ ELECTRICAL FAULTS

Beware of parts which are live!

Remove 3 Amp. Fuse in the control panel

while working on the generator to prevent the

engine from starting

A failure code is displayed when a hardware failure at the

generator is detected

5.1.1

General

If any problem should occur, check basic conditions and

examine all external wiring, switch gear and circuit

breakers. Also check if measuring instruments give the

correct value. If in doubt, measure directly on the

alternator terminals with an independent instrument.

These measurements should only be carried out by an

experienced electrician

If during these measurements the engine immediately

stops after starting and an error code is displayed at the

remote control panel ( “AC VOLTAGE”), one can start the

generator by means of a “service start” at the service

menu (see paragraph “service start” of the user’s manual

of the Digital Diesel Control). By doing this, the generator

will keep running for 2 minutes before it stops. This offers

you the possibility to carry out measurements to

investigate the cause of the failure.

Check if the engine is running correctly at 1500 RPM (50

Hz) according to its settings and does as well under load.

A RPM drop of 1% at full load is acceptable. Therefore a

no load setting should be at 1515 RPM = 50.5 Hz. Under

no circumstances should the RPM under full load be below

1485 RPM = 49.5 Hz.

When 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

Coolant temperature is too high

OIL PRESSURE

Oil pressure failure

AC VOLTAGE

Generator AC output voltage is either too high or too low

HIGH CURRENT

Generator is in overload

FREQUENCY

Output frequency of the generator is too low

Содержание W-SQ12

Страница 1: ...CATIONS W SQ12 1500 RPM Mobile diesel generating set 230V 50Hz Digital Diesel Control WHISPER POWER BV Kelvinlaan 82 9207 JB Drachten Nederland Tel 31 512 571550 Fax 31 512 571599 www whisperpower eu Art nr 40200481 V1 January 2009 ...

Страница 2: ...e control 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 12 2 5 6 Control 13 2 5 7 Remote control 13 2 5 8 Hour counter 13 2 5 9 Load indicator 13...

Страница 3: ...3 4 3 Regular maintenance 24 4 3 1 Maintenance schedule 25 4 3 2 Putting out of service 25 5 TROUBLE SHOOTING 26 5 1 Alternator electrical faults 26 5 1 1 General 26 5 1 2 Trouble shooting table alternator 27 5 2 Engine faults 28 5 2 1 General 28 5 2 2 Trouble shooting table engine 29 5 2 3 Warnings 31 5 2 4 Service address 31 5 3 Special procedures alternator 32 5 3 1 Residual voltage check excit...

Страница 4: ...on to special warnings instructions or procedures which if not strictly observed may result in electrical shock which will result in severe personal injury or loss of life DANGER Realise that people are not used to have 230V available on a vehicle Put warning signs on wall sockets and on junction boxes Instruct non regular users of the vehicle Warn maintenance personal of garages that do service o...

Страница 5: ... a credit will not be issued For example if a Printed Circuit Board is returned with clear damage caused by seawater guarantee will be refused Freight costs to deliver spares by normal mail or carriers is covered under guarantee Special services like express mail overnight delivery etc are not covered Taxes and duties are not covered For shipments to remote areas any additional costs incurred over...

Страница 6: ...s 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 1500 rpm 5 CURRENT shows the maximum current that is acceptable at the specified frequency voltage and power factor 6 WEIGHT shows the net dry...

Страница 7: ...to 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 measures...

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

Страница 9: ...des a diesel engine which 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...

Страница 10: ...plug 4x 07 Fuel injection pump 08 Fuel solenoid 09 Engine oil filter 10 AC power output 11 Remote control 12 Power take off PTO 13 Dry exhaust 1 14 Expansion tank Ø8mm 20 Engine speed adjusting screw 21 Injection pump air bleeding screw 22 Engine serial number 23 Coolant generator out 24 Fuel out Ø8mm 25 Fuel in Ø8mm 26 Coolant generator in 27 Coolant engine in 28 Fuel lift pump 29 Hoist eye front...

Страница 11: ...engine coolant 42 Rocker cover 43 Filler cap engine oil 44 Temperature switch coolant 45 Thermostat housing 46 Failsafe 47 Air cleaner element 48 Hoist eye rear 50 Exhaust manifold watercooled 51 Rubber engine mounting 52 Starter motor solenoid 53 Starter motor 54 Coolant generator out 55 Water pump of the alternator cooling circuit 56 V belt 66 Engine coolant pump 67 Alternator 12VDC ...

Страница 12: ...oad 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 SQ12 generating set is based on the Mitsubishi S4L2 4 cylinder diesel engine The engine is indirectly injected The engine is water cooled and the...

Страница 13: ...quirements of API class CD CF or CF_4 It is very important to use the correct oil specification Very often local oil suppliers recommend a higher class because they assume that a higher class is allowed This is not the case One should not follow these recommendations Using the wrong specification will cause high oil consumption 2 Oil viscosity We recommend a multigrade oil 15W40 3 Oil capacity Exc...

Страница 14: ...c start stop ELECTRICAL SPECIFICATIONS Output voltage 230V 50 Hz alternating current AC single phase Output rating 12 kVA 12kW at power factor cos phi 1 Voltage tolerance 5 Frequency tolerance 1 electronic governor Alternator brushless four pole synchronous Voltage regulation Capacitor AVR optional MECHANICAL SPECIFICATIONS Supply includes Sound shield with steel base mounted on rubber anti vibrat...

Страница 15: ...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 L ...

Страница 16: ...INFORMATION 16 January 2009 W SQ12 for mobile applications EN 2 5 15 Lay out control wiring Fig 10 Electrical Diagram control wiring W SQ12 Optional control for two speeds fans See chapter 2 5 17 ...

Страница 17: ...INFORMATION EN W SQ12 for mobile applications January 2009 17 2 5 16 Electrical diagrams 230 V AC 50 Hz Figure 13 Electrical diagram 230 V AC 50 H ...

Страница 18: ...VDC K1 K2 230 115VAC 200VA TRAFO 230VAC Fig 13 Electrical diagram fan control using 230V AC radiator fans with two speeds fans optional FUSE 5A FUSE 6 3A FUSE 6 3A FUSE 5A FUSE 5A 15 16 5 6 7 8 13 14 11 1 4 2 3 K2 K1 K2 K1 BAT 12V PUMP 12V GENERATOR 230VAC L1 K1 BAT 12V GENERATOR 230VAC N 230VAC 230VAC 45 35 C 80 70 C THERMOSTAT COOLER ENGINE GENERATOR RADIATOR COOLER ENGINE RADIATOR COOLER GENERA...

Страница 19: ...e 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 and other m...

Страница 20: ...d 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 this...

Страница 21: ...starting 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 W SQ12 is designed so as not to overheat even under extreme conditions Do not run th...

Страница 22: ...ad 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 necessa...

Страница 23: ... 7 Air filter element The interval for cleaning of the air filter element figure 20 strongly depends on environmental conditions Check the condition of the element at least every 500 running hours but should be at least every six months Fig 20 Air filter element 4 2 8 Air strainer element The W SQ12 for mobile applications is standard supplied with an air strainer element figure 21 Strainer change...

Страница 24: ...lant pump Replace the oil filter Replace the fuel filter Replacement depends or the condition of the fuel We recommend replacement every 300 hours Isolate the fuel supply and change the element EVERY 500 HOURS Check the air strainer element and the air filter element Replace the impeller of the alternator coolant pump When replacing the impeller the gasket between the pump case and the cover shoul...

Страница 25: ...lean radiators 1000 hours Replace or clean the air strainer element 2000 hours Check lubricating oil pressure 2000 hours Check injector and injection pressure 2000 hours Replace or clean the air filter element 2000 hours 4 3 2 Putting out of service When not using the generating set for a longer period it is recommended to execute an engine preservation procedure 1 Clean the engine 2 Loosen the fu...

Страница 26: ...e user s manual of the Digital Diesel Control By doing this the generator will keep running for 2 minutes before it stops This offers you the possibility to carry out measurements to investigate the cause of the failure Check if the engine is running correctly at 1500 RPM 50 Hz according to its settings and does as well under load A RPM drop of 1 at full load is acceptable Therefore a no load sett...

Страница 27: ...tion it is ok Generator is overloaded Switch off a load part off consumers Engine is not reaching the rated RPM Refer to engine RPM problems Defective capacitor Check capacitor and replace if necessary refer to special procedures Generator voltage too high more than 245V 130V Engine is running too fast RPM too high Check engine speed and adjust refer to special procedures Over energising due to de...

Страница 28: ...om battery problems or poor battery cable connections When the engine is cranking well starting problems almost always originate from lack of fuel or air bubbles in the fuel pipes A failure code is displayed when a hardware failure at the generator is detected Failure code Problem COMMUNICATION Communication error between the panel end the generator LOW START BAT Starter battery voltage too low AL...

Страница 29: ...d Air in fuel lines 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 re...

Страница 30: ...re 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 information on the alarm system Bypassing the switches can help to confirm the failure Engine stops by itself Overload or short circuit Switch off the consumers and test for short circuit Lack of fuel Check...

Страница 31: ...l pump Check and replace if nescessary Injector blocked Have the injector checked 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 rel...

Страница 32: ...terminal end and the forward and reverse resistance checked A healthy diode 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 I...

Страница 33: ...26 Cylinder head bolts The clearance of both intake and exhaust valves should be 0 25 mm in cold condition Set the piston of the first cylinder to be adjusted to top dead centre T D C of compression stroke 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 27 First align the T D C mark for the No 1 cylind...

Страница 34: ...ator 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 the co...

Страница 35: ...ft 50201811 Bearings 2 pcs 50209014 O ring 50209017 Seals 2 pcs 50209015 Clips 1 set 50209019 O ring 50201814 50209010 Pump repair kit B same as repair kit A excluding the shaft 5021811 and O ring 50201814 50201060 Capacitor xx micro farad 2 pcs xx give value when ordering 50209132 Measuring coil 50201890 Rotary diode 50201482 Alternator bearing including O ring 50209140 Voltage regulator optional...

Страница 36: ...ler kit Bearing 50209014 50209016 Circlip 50201811 Shaft Male hose connector 50221031 Pumphousing 50201414 Seal 50209015 50209018 Screwcover Cover type M12 50201401 Gasket 50209012 Impeller K M 50209013 50221007 Male hose connector O ring 50209017 Bearing 50209014 50209019 Circlip 50209019 Circlip Figure 29 water pump complete Whisper Power type M12 ...

Страница 37: ...MAINTENANCE LOG EN W SQ12 for mobile applications January 2009 37 MAINTENANCE LOG first service after 50 hours hour counter remarks next service every 150 hours hour counter ...

Страница 38: ...NOTES 38 January 2009 W SQ12 for mobile applications EN NOTES ...

Страница 39: ...NOTES EN W SQ12 for mobile applications January 2009 39 NOTES ...

Страница 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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