WEICHAI WPG13.5 Operation Manual
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WEICHAI WPG13.5 Operation Manual

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Operation & Maintains Manual of Weichai Group
Diesel Gen-set
Version No.: V01
Weichai Heavy Machinery Co., Ltd.

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Summary of Contents for WEICHAI WPG13.5

  • Page 1 Operation & Maintains Manual of Weichai Group Diesel Gen-set Version No.: V01 Weichai Heavy Machinery Co., Ltd.
  • Page 2 Foreword Before operating the Gen-set, please read this Operation Manual carefully. This user manual is mainly used to guide customers how to use this equipment, describes structural composition, operation and use, daily maintenance and care, fault diagnosis and measures that shall be taken in details, is helpful for operators and maintenance personnel to use and maintain the Gen-set correctly and contributes for judgment analysis and troubleshooting when the Gen-set malfunctions, in order to ensure that the equipment can be put into normal operation rapidly.

  • Page 3: Table Of Contents

    Contents CHAPTER 1 SAFETY ..................1 I. SAFETY RULES .................... 1 II. SAFETY SYMBOLS ..................2 CHAPTER 2 OPERATING CONDITIONS AND PURPOSES ........5 I. DESCRIPTION ON MODEL OF THE GEN-SET ........5 II. DESCRIPTION ON POWER OF THE GEN-SET ........5 III.
  • Page 4 I. INSPECTIONS BEFORE COMMISSIONING ........... 43 II. PREPARATIONS BEFORE COMMISSIONING ........44 III. COMMISSIONING OF THE GEN-SET ........... 50 CHAPTER 8 OPERATION OF THE GEN-SET ............55 I. PREPARATIONS AND INSPECTIONS BEFORE OPERATION ....55 II. OPERATION OF THE GEN-SET .............. 56 CHAPTER 9 MAINTENANCE AND CARE OF THE GEN-SET ......

  • Page 5: Chapter 1 Safety

    1. Electric shock may cause injuries of operators 1.1 Casing of Gen-set must be grounded, in order to prevent endangerment to personal safety of operators caused by live casing. Because Weichai Gen-set is designed with safe grounding system, customers only need to install as per local electric power rules and regulations;...

  • Page 6: Safety Symbols

    Diesel Gen-set Operation Instructions even death because hydrogen may immediately cause an explosion if it contacts with electric arc or spark; 2.2 When the Gen-set is operating or hot, do not add fuel into fuel tank. It would be very dangerous if fuel contacts with hot body of diesel engine and exhaust pipe, etc. 3.
  • Page 7 Diesel Gen-set Operation Instructions Following safety symbols used on Weichai Gen-set are used to remind operators and maintenance personnel of the fact that serious personal injuries or significant property losses would be caused if they do not follow these warnings. Meanings that these safety symbols express are as shown in Table 1-1.
  • Page 8 Diesel Gen-set Operation Instructions Beware of hot surface Beware of electric shock Beware of rotating parts Beware of auto starting Must be grounded Lift up the Gen-set from here Transport with a forklift from here...

  • Page 9: Chapter 2 Operating Conditions And Purposes

    Its allowable average output power in an interval of 24h shall not be greater than 70% of rated power. An interval of 1h overload power supply is allowable in every 12h operation of Weichai Gen-set and its overload capacity is 10% of rated output power.

  • Page 10: Environment Adaptability Of The Gen-Set

    2. Rated capacity: for the Gen-set whose power factor is 0.8 (lagging), its rated capacity shall be 1.25 times of rated power. 3. Reserve capacity: reserve capacity of Weichai Gen-set is 1.1 times of rated capacity. III. Environment adaptability of the Gen-set Under following environmental conditions, the Gen-set shall be able to operate normally and output rated power.

  • Page 11: Range Of Application

    When the Gen-set is going to be used under non-standard environmental conditions, users shall correct power of the Gen-set according to change of environmental conditions. For details of correction factor, please consult Weichai Power Generation Equipment Co., Ltd. V. Range of application...

  • Page 12: Chapter 3 Overview On Main Structure Of The Gen-Set

    Diesel Gen-set Operation Instructions Chapter 3 Overview on Main Structure of the Gen-set 1. Inlet of fuel delivery pump 2. Silencer 3. Air filter 4. Control panel Breaker 6. Alternator 7. Ground connection 8. Absorber 9. Chassis Oil drain hole 11.
  • Page 13 Alternator is a device converting mechanical energy into electrical energy. 1. Structure of alternator The Weichai Gen-set adopts a brushless three-phase synchronous alternator. As shown in Figure 3-2, the alternator mainly consists of main stator (armature), main rotor (magnetic field), exciter stator (magnetic field), exciter rotor (armature), rotary rectifier, automatic voltage regulator (AVR) and outlet box, etc.
  • Page 14 Figure 3-3 Alternator operating principles schematic diagram 3. Automatic voltage regulator (AVR) AVR of Weichai alternator is a half-wave phased thyratron type automatic voltage regulator and one part of alternating-current brushless alternator excitation system. Except regulating voltage of alternator, AVR is equipped with low-speed and no-detection signal protection function, in order to ensure that alternator is controlled in a safe and reliable way.
  • Page 15 Diesel Gen-set Operation Instructions 3.1 AS440 Stability selection Jumper Frequency selection Jumper LED indicator light Figure 3-4 AS440 Structure diagram 1) Generally, terminal 8 and Z2 are short-connected. However, if the alternator is equipped with auxiliary winding, they shall be disconnected and connected to auxiliary winding;...
  • Page 16 Diesel Gen-set Operation Instructions Excitation rotor Main rotor (magnetic field) Main stator (armature) Excitation stator Rotary rectifier Manual voltage potentiometer Low voltage mode Note: AVR input terminal Regulating current Manual voltage potentiometer shall be equipped with twin-core transformer shielded wire connecting to alternator casing or being grounded directly.
  • Page 17 Diesel Gen-set Operation Instructions Table 3-2 Function list of AS440 adjustment potentiometer No. in Control button Function Direction of adjustment figure Adjust output voltage of Turn clockwise to Voltage alternator increase output voltage Droop (applicable for Droop is 5% when power Turn clockwise to parallel connection) factor of Gen-set is 0...
  • Page 18 Diesel Gen-set Operation Instructions 1) F+ and F- terminal of the regulator shall be connected to positive and negative electrode of brushless exciter’s excitation winding respectively. If DC resistance of excitation winding is less than 21Ω and exciting current under full load is not greater than maximum continuous rated current of regulator, excitation winding must be connected with a enough large resistor in parallel until the resistance reaches to 21Ω;...
  • Page 19 Diesel Gen-set Operation Instructions 4) Stability adjustment shall be selected as per Table 3-3. Table 3-3 Stability selection list Serial number Power range Response speed Slow 〈100kW No connection 〈100kW Fast Fast 〉100kW 5) See Table 3-4 for roles and adjustment methods of AVR adjustment potentiometer. Table 3-4 Function list of AS480 adjustment potentiometer Control button Function...

  • Page 20: Control Panel

    Diesel Gen-set Operation Instructions procedures shall be followed: Let the Gen-set to operate without load and check if its speed is correct or not; Turn stability knob to the end clockwise and then turn it counterclockwise slowly until voltage of alternator starts to fluctuate. Note: correct setting will be completed just by slightly turning clockwise from this position (namely, at this point, voltage of alternator is stable, but it is also very close to unstable zone).
  • Page 21 Diesel Gen-set Operation Instructions Figure 3-8 Control panel diagram 1. DSE6020 display module 6020 module of Deep Sea Electronics is an AMF/ATS module which is able to display various parameters of engine (speed, oil pressure, water temperature, fuel level and battery voltage), parameters of alternator (frequency, three-phase voltage (L-L and L-N) and current), power parameters of alternator (kVA, kW, PF, kVAR, kWh, kVAH and kVARH), parameters of mains power (frequency, three-phase voltage (L-L and L-N)), contains 7 inputs and 6 outputs (4 outputs can be customized...
  • Page 22 Diesel Gen-set Operation Instructions Function Display various parameters of Gen-set Page down Press this button to display detail information of current page Stop operation of Gen-set Press this button to enter into manual mode and adjust parameters (-) Simulate state of loss of mains power and adjust parameters (+) Press this button to enter into AUTO mode Silence button...
  • Page 23 Diesel Gen-set Operation Instructions Alarm indication light, the module will record the latest 5 alarm records for ease of maintenance 2. Power switch Control power on/off of control panel of the Gen-set. 3. Emergency stop button Press this button to stop the Gen-set immediately when any emergency occurs. And, the Gen-set is unable to be started under this state.
  • Page 24 Diesel Gen-set Operation Instructions Structure of the control panel of DSE7320 module is as shown in Figure 3-10. DSE7320 module Door lock Power switch Emergency stop button Air switch Figure 3-10 Control panel drawing 1. DSE7320 display module 7320 module of Deep Sea Electronics is an AMF/ATS module which is able to display various parameters of engine (speed, oil pressure, water temperature, fuel level and battery voltage), parameters of alternator (frequency, three-phase voltage (L-L and L-N) and current), power parameters of alternator (kVA, kW, PF, kVAR,...
  • Page 25 Diesel Gen-set Operation Instructions Figure 3-11 DSE6020 module Function Gen-set stop and fault resetting button Gen-set manual mode button Mains power fault simulation and test button Gen-set AUTO mode button...
  • Page 26 Diesel Gen-set Operation Instructions Silence button Gen-set start button (operative under manual mode) Alternator switching-on button Mains power switching-on button (applicable for the case when AMF function is used) Enter button Left and right menu navigation button, used to select menu in turn Up and down selection button, used to query parameters in each menu in turn...
  • Page 27 Diesel Gen-set Operation Instructions 15. When mains power (mains power system supplies power to loads, which is applicable when AMF function is used) is switched on, green light turns on 16. When common alarm is generated, green light turns on 17.
  • Page 28 Diesel Gen-set Operation Instructions 3. Electrical schematic diagram Figure 3-12 Electrical Schematic Diagram of DSE6020 Module’s Common Functional Gen-set（Mechanical Governing）...
  • Page 29 Diesel Gen-set Operation Instructions Figure 3-13 Electrical Schematic Diagram of DSE6020 Module’s Automatic Change-Over Gen-set（Mechanical Governing）...
  • Page 30 Diesel Gen-set Operation Instructions Figure 3-14 Electrical Schematic Diagram of DSE7320 Module’s Automatic Gen-set（Mechanical Governing）...
  • Page 31 Diesel Gen-set Operation Instructions Figure 3-15 Electrical Schematic Diagram of DSE7320 Module’s Automatic Gen-set（Mechanical Governing）...

  • Page 32: Chapter 4 Main Specifications And Technical Parameters Of The Gen-Set

    Diesel Gen-set Operation Instructions Chapter 4 Main Specifications and Technical Parameters of the Gen-set WPG13.5B1 WPG16.5B1 WPG22B1 WPG27.5B1 WPG33B1 WPG41B1 WPG55B1 WPG68.5B1 Model Rated power (kW) Rated voltage (V) Rated frequency (Hz) Rated current (A) 1500 1500 1500 1500 1500 1500 1500 1500...
  • Page 33 Diesel Gen-set Operation Instructions Battery voltage (V) - Battery capacity (A·h)-Shuangdeng 498×415 498×415 498×415 498×415 498×415 498×415 498×415 498×415 Cooling area (mm) WPG13.5F1 WPG16.5F1 WPG22F1 WPG27.5F1 WPG33F1 WPG41F1 WPG55F1 WPG68.5F1 Model Rated power (kW) Rated voltage (V) Rated frequency (Hz) Rated current (A) 1500 1500...
  • Page 34 Diesel Gen-set Operation Instructions 1350×700×1060 1350×700×1060 1430×700×1160 1600×760×1210 1600×760×1210 1680×760×1210 1720×760×1411 1860×740×1411 Overall dimensions (mm) Net weight of the Gen-set (kg) Battery voltage (V) - Battery capacity (A·h)-Shuangdeng 498×415 498×415 498×415 498×415 498×415 498×415 498×415 498×415 Cooling area (mm) Note: 1. Above main specifications and technical parameters of the Gen-set are for reference only. We reserve the right to optimize and change design the Gen-set and change parameters without further notice.

  • Page 35: Chapter 5 Transportation Of The Gen-Set

    The diesel Gen-set shall be provided with necessary safety protections during transportation. The wooden carrying case, standard configuration of Weichai Gen-set, can prevent the Gen-set from being suffered from damages caused by external shocks effectively. In addition, the Gen-set shall be firmly secured during transportation, in order to prevent loosening or damage of parts caused by vibration.

  • Page 36: Chapter 6 Installation Of The Gen-Set

    Diesel Gen-set Operation Instructions Chapter 6 Installation of the Gen-set I. Preparations before installation 1. Unpacking of the Gen-set Before unpacking, clean dust and check if body of the case is damaged or not at first. Then, check case number and quantity and do not damage the machine during unpacking.
  • Page 37 Diesel Gen-set Operation Instructions Gen-set; 3) The equipment room shall provide enough space for maintenance of the Gen-set and distance from edges of installed Gen-set to wall surface shall not be less than 1,500mm; 4) There are shall be enough space for arrangement of exhaust pipe at height direction of equipment room and height of equipment room for 10~50kW series Gen-set shall not be less than 3,500mm.
  • Page 38 (L)×1300mm (W)×200mm (H). 3. Transportation of the Gen-set Common chassis of Weichai Gen-set is designed with lifting eye and forklift groove and the Gen-set can be transported and installed by using crane or forklift. When crane is used, in order to prevent the Gen-set from being titled when being lifted up, four steel wire ropes whose length is the same shall be used.
  • Page 39 Diesel Gen-set Operation Instructions Note: for outdoor lifting, do not lift up the Gen-set in heavy windy days. Warning: all people shall be kept away from lifted Gen-set. 4. Installation of the Gen-set The Gen-set shall be connected to foundation with anchor bolts or proper cushions. Fixing chassis of the Gen-set to foundation with anchor bolts can not only reduce vibration effectively, but also can prevent moving of the Gen-set.
  • Page 40 Diesel Gen-set Operation Instructions ventilation system when necessary. Suggestion: effective air intake/exhaust area of 10~50kW series Gen-set shall not be less than 0.6m and 0.5m respectively. 6. Smoke exhaust system Smoke exhaust system refers to the exhaust pipe connecting from smoke exhaust port of diesel engine to outside of the equipment room.
  • Page 41 Diesel Gen-set Operation Instructions 6.4 Owning to the fact that temperature of exhaust pipe is high, in order to prevent burns and prevent rising of temperature in equipment room caused by radiant heat, heat insulation treatment shall be carried out. And, heat insulation materials shall be wrapped with glass fiber or aluminum silicate effective for heat insulation and noise reduction.
  • Page 42 Diesel Gen-set Operation Instructions manually, it is acceptable to refill fuel to daily-use fuel tank by a manual pump or automatic refueling system; 3) Outlet of daily-used fuel tank shall be at a position which is 0.5m above foundation of the Gen-set (the same with height of fuel injection pump of diesel engine). The outlet shall not be too high (not 1m higher than fuel injection pump), in order to avoid its pressure from exceeding maximum pressure resistance of fuel pump of the Gen-set;...
  • Page 43 In addition, influence factors are many and calculation is complex also. Weichai recommends you to select cable as per following specifications:...
  • Page 44 Diesel Gen-set Operation Instructions laying, cable trench laying, tunnel laying, underwater laying and laying along the wall, etc. Selection of cable laying method depends on engineering conditions, environmental characteristics, cable type and quantity, and other factors and shall be carried out by adhering to the principles of reliable operation, ease of maintenance and economic and reasonable technology.
  • Page 45 Diesel Gen-set Operation Instructions Lighting facilities: equipment room shall be equipped with necessary lighting facilities.

  • Page 46: Gen-Set

    Diesel Gen-set Operation Instructions III. Standard equipment room arrangement of the Gen-set Exhaust pipe Fire-fighting Exhaust pipe suspension equipment Sewage trench (80mm in depth and 80mm in width) Bellow Silencer Air exhaust Air direction Air inlet louver window pipe Cold air Hot air Cold air Concrete...

  • Page 47: Chapter 7 Commissioning Of The Gen-Set

    Diesel Gen-set Operation Instructions Chapter 7 Commissioning of the Gen-set Carry out commissioning as per following methods after the Gen-set is installed: I. Inspections before commissioning 1. Areas at around Gen-set shall be cleaned up and unsafe objects shall be moved away, in order to prevent operation from being influenced or danger from being caused and ensure that intake/exhaust duct for ventilation of equipment room is not blocked;...

  • Page 48: Preparations Before Commissioning

    Diesel Gen-set Operation Instructions Danger: when cleaning battery, do not smoke or carry out fire-related works nearby because the hydrogen generated during electrolysis of battery may cause an explosion. 7. Check restriction indicator of air filter and clean the filter if restriction display appears.
  • Page 49 Diesel Gen-set Operation Instructions Table 7-1 Domestic long-life anti-freeze Grade JFL-318 JFL-336 JFL-345 Item Content of ethylene glycol (%) Specific gravity 1.05 1.074 1.082 (15.6 ) ℃ Boiling point ℃ 104.5±1 108.5±1 110±1 Freezing point ℃ -18±1 -36±1 -45±1 Applicable minimum air temperature ℃...
  • Page 50 Select SAE15W/40 grade lubricating oil in Central China; Select SAE20W/50 grade lubricating oil in southern region. You are recommended to use Weichai Power’s dedicated 15W-40 engine oil which is mixed with imported high-quality base oil and well-chosen additives and sold by various service outlets at a unified price in China.
  • Page 51 Diesel Gen-set Operation Instructions engine and detect engine oil level by the dipstick on oil pan. The level shall be proper when it is higher than L (lower level) scale mark and lower than H (higher level) scale mark. Figure 7-2 Engine oil level 3.
  • Page 52 Diesel Gen-set Operation Instructions No.-35 light diesel oil: applicable for the regions where lowest air temperature is above -29 ; ℃ No.-50 light diesel oil: applicable for the regions where lowest air temperature is above -44 ; ℃ 3.2 Method for refueling Fill fuel to daily-use fuel tank fully.
  • Page 53 Diesel Gen-set Operation Instructions 2) Bleed air in high pressure fuel pipe and fuel pump Loosen nuts and drive diesel engine to rotate with starter to bleed air in fuel pump and high pressure fuel pipe until fuel flows from high pressure fuel pipe continuously. Then, stop the operation and tighten nuts.

  • Page 54: Commissioning Of The Gen-Set

    Diesel Gen-set Operation Instructions prohibited; 4) Air switch is in switching-off state. 6. Testing insulation resistance 1) Open outlet box cover plate of alternator to remove wiring on main stator (armature) of alternator AVR, namely No.7 and No.8 wiring of AS440 and AS480 (for SE350, remove No.3 and No.4 wiring);...
  • Page 55 Diesel Gen-set Operation Instructions Finally, press manual mode button on control panel to switch to the manual mode, and LED indicator light turns on. After the controller is in manual mode, press start button again to start the Gen-set manually; if you want to stop the Gen-set, press stop button.
  • Page 56 Diesel Gen-set Operation Instructions 4) Check if there is any abnormal noise or vibration and check connection and fastening condition of various parts; 5) Check if exhausting is normal or not. Belching of small amount of black smoke immediately after starting of the Gen-set is normal. If the Gen-set is equipped with idling/rated speed switch and operates normally after being started, turn throttle control handle of diesel engine to “RATED SPEED”...
  • Page 57 Diesel Gen-set Operation Instructions 2.2 Operation with load If the Gen-set operate normally, let the Gen-set operate under rated speed for 3~5min and close breaker after the Gen-set warms up to let the Gen-set operate under load. At this time, inspect operating condition of the Gen-set. The main inspection items are as follows: 1) Check speed and frequency of the Gen-set (normal speed and frequency of the Gen-set is separately 1,500r/min and 50Hz).
  • Page 58 Diesel Gen-set Operation Instructions 1) Remove loads at first, proceed to switching-off operation and let the Gen-set operate without load for 3~5 minutes after being unloaded; 2) Press stop button , stop electromagnet operates, pull stop handle to stop position to stop operation of the Gen-set; 3) Finally, turn power switch to “OFF”...

  • Page 59: Chapter 8 Operation Of The Gen-Set

    Diesel Gen-set Operation Instructions Chapter 8 Operation of the Gen-set I. Preparations and inspections before operation 1. Areas at around Gen-set shall be cleaned up and unsafe objects shall be moved away, in order to prevent operation from being influenced or danger from being caused and ensure that intake/exhaust duct for ventilation of equipment room is not blocked;...

  • Page 60: Operation Of The Gen-Set

    Diesel Gen-set Operation Instructions 10. Make sure that air switch of the Gen-set is OFF; 11. Connect negative battery cable. II. Operation of the Gen-set 1. Starting of the Gen-set Turn power switch on control panel to “ON” position at first and display module of control panel is able to display various parameters normally;...
  • Page 61 Diesel Gen-set Operation Instructions 3) Check if water temperature and oil pressure of the Gen-set is normal or not. Water temperature shall be lower than 95 ℃ and oil pressure shall be higher than 0.15Mpa; 4) Check if lines of fuel, lubrication and cooling system leak or not; 5) Check if belched smoke is normal.
  • Page 62 Diesel Gen-set Operation Instructions Note: be sure that the Gen-set is not operated under no-load state continuously for more than 30 minutes, in order to prevent leakage of lubricating oil of the Gen-set. Warning: do not try to touch exhaust pipe, turbocharger, high-temperature coolant &...
  • Page 63 Diesel Gen-set Operation Instructions 4.4 If you want to stop the Gen-set directly, press stop button two times successively; 4.5 Turn power switch to “OFF” position; 4.6 Remove connecting cable from negative electrode of battery and protect it with insulation tape. Note: never stop the Gen-set operating with loads.

  • Page 64: Chapter 9 Maintenance And Care Of The Gen-Set

    Diesel Gen-set Operation Instructions Chapter 9 Maintenance and Care of the Gen-set I. Maintenance and care schedule Interval Contents Clean oil stains and dust on Gen-set Check level of diesel oil, engine oil and coolant Daily Check if there is any air, oil or water leakage Check if all electric circuits are getting loose or damaged or not Clean dust in dust exhausting bag of air filter Change engine oil and element of oil filter...

  • Page 65: Maintenance And Care Operation

    Diesel Gen-set Operation Instructions Clean radiator Clean oil cooler or replace core of oil cooler if it is blocked Check and adjust angle of advance Check tightness of air valve Check if crankcase blows by and if belched some is blue, replace piston ring when necessary.
  • Page 66 Diesel Gen-set Operation Instructions Coolant level: when coolant level is low, fill proper amount of coolant into water tank until coolant level in radiator is 5cm below filler. 2. Replacing engine oil and oil filter element Replacement is necessary after first 50 hours operation of the Gen-set. Then, replacement is necessary every 200h operation as per following specific procedures: 2.1 Start the Gen-set until water temperature reaches to 60 .
  • Page 67 Diesel Gen-set Operation Instructions 2.5 Install filter to filter cover and then tighten it until washers contact with surface of filter cover closely. Then, retighten it 3/4~1 turn(s) more to seal it up. 2.6 Check and clean drain plug and washers and then reinstall and retighten them. 2.7 Fill new lubricating oil until its level is between the upper and lower scale mark of oil dipstick.
  • Page 68 Diesel Gen-set Operation Instructions Remove filter element from air filter and gently pat end face or flush reversely (from inside to outside) with compressed air to remove dust, as shown in Figure 9-3. Figure 9-3 Cleaning of air filter Note: do not damage the filter paper while flushing, wash filter paper with water or oil, or pat or knock element with force.
  • Page 69 Diesel Gen-set Operation Instructions Rust cleaning procedures of radiator are as follows: 1) Drain water in the system, remove and close interface connecting pipes and oil engine. 2) Prepare anti-acid solvent at the concentration of 4% and fresh water, add anti-acid solvent into water and pay attention to not reverse the order.
  • Page 70 Diesel Gen-set Operation Instructions 6. Drying of alternator 6.1 Cold-state operation If a normal alternator is left out of operation for a long period of time in a dusty and moisture environment, simply operate the Gen-set with connecting wire (F1 and F2 connecting wire of AS440 and AS480, F+ and F- connecting wire of SE350) of excitation stator (magnetic field) of AVR is disconnected for 10 minutes or longer.
  • Page 71 Diesel Gen-set Operation Instructions with safe operation procedures of malfunctioned Gen-set. At first, carry out all mechanical and electrical safe operations related to the Gen-set and site, in order to ensure operation safety of alternator. Complete short connection of output end of Gen-set with short-circuit plates which can withstand rated current of alternator.
  • Page 72 Diesel Gen-set Operation Instructions If the Gen-set does not operate immediately, make sure that condensation removing heater installed on alternator is energized and operates normally. Measuring of insulation resistance is still necessary before starting of operation next time. Warning: never carry out short connection of three-phase winding when AVR and alternator is connected to a loop as winding will be damaged when current exceeds rated current of the alternator.
  • Page 73 Diesel Gen-set Operation Instructions temperature of winding is 20 . ℃ If insulation resistance is still lower than 1MΩ after above drying process, carry out polarization test of coil. If all parts cannot meet the requirement of 1MΩ insulation resistance, wind the coil again or clean alternator again.
  • Page 74 Diesel Gen-set Operation Instructions 1) After the Gen-set is warmed up, clean engine oil filter and add anti-rust oil to oil pan of diesel engine. 2) Drain all diesel oil in fuel system and fill a mixture of 90% diesel oil and 10% anti-rust oil to protect the entire fuel lines.
  • Page 75 Diesel Gen-set Operation Instructions 8.4 Followings shall be paid attention to during storage of battery: it shall be kept in a dry, clean and well-ventilated room in which temperature is 5~25 ; be kept away ℃ from direct sunlight, heat source, any liquid and hazardous substances; do not be placed upside down or on the side;...

  • Page 76: Chapter 10 Common Failures And Troubleshooting

    Diesel Gen-set Operation Instructions Chapter 10 Common Failures and Troubleshooting 1. Diesel engine does not start No. Causes Troubleshooting Starting system fails-starter does not operate Power of control system is not Connect power of control system connected Battery is low in level or damaged Recharge or replace the battery Fuse in control chamber operates Replace fuse...
  • Page 77 Diesel Gen-set Operation Instructions start Air intake system leaks air Inspect and maintain Intake manifold is blocked Clean Clean air filter (see Chapter 9 for Air filter malfunctions specific method) Intake or exhaust valve leaks air Adjust valve clearance Air cylinder leaks air Replace piston ring 2.
  • Page 78 Diesel Gen-set Operation Instructions Blue some-burning of engine oil Drain surplus engine oil until Too much engine oil is filled to oil pan and level of engine oil in oil pan is enters into combustion chamber when between H and L oil level of diesel engine operates dipstick.
  • Page 79 Diesel Gen-set Operation Instructions 3. Engine hunting No. Causes Troubleshooting Fuel supply control rod of fuel injection pump moves inflexibly or normal Contact with after-sale service functioning of regulator is damaged, then personnel to recalibrate or amount of pumped fuel fluctuates and replace.
  • Page 80 Diesel Gen-set Operation Instructions digital tachometer. Contact with after-sale service personnel to Speed sensor malfunctions maintain or replace. Check if fuel supply pipe or fuel filter is Fuel supply system is blocked blocked. If necessary, replace it. There is water in diesel Replace fuel and add oil-water separator Adjustment of throttle control Check travel of accelerator...
  • Page 81 Diesel Gen-set Operation Instructions 1,500r/min UFRO setting Reset UFRO as shown below Check alternator and AVR as shown below Other reasons according to procedures of excitation separation test method 5.1 Inspection of Remanence Voltage Remove AVR cover plate, and wires (F1 and F2 if AS440 or AS480 is used, or F+ and F- if SE350 is used) of excitation stator (magnetic field) when the Gen-set is still;...
  • Page 82 Diesel Gen-set Operation Instructions Stop the Gen-set. Disconnect the battery from terminals F1 and F2 if AS440 or AS480 is used, or terminal F+ and F- of SE350 is used. Restart the Gen-set, the alternator shall run normally. If there is no voltage, the alternator or AVR line may have problems.
  • Page 83 Diesel Gen-set Operation Instructions below. Disconnect wires F1 and F2 (or F+ and F- of SE350) of excitation stator (magnetic field) from AVR, and supply power to F1 and F2 (or F+ and F- of SE350) with a 12V DC power source. Start the Gen-set and operate at rated speed.
  • Page 84 Diesel Gen-set Operation Instructions 1) If the voltage is balanced but too low, main excitation winding or rotating diode may have problems. Please execute the steps below to identify the problem: Rectifier diode The diode on main rectifying component can be measured with multimeter. Disconnect the flexible conductor connected to each diode at terminal, and measure its forward and reverse resistance.
  • Page 85 Diesel Gen-set Operation Instructions rectifying plates. Corresponding lead must be disconnected before reading. 5.3.2 Voltage Imbalance of Primary Output Terminal Voltage imbalance shows that main stator winding or main cable connected to circuit breaker may have problems. Note: during excitation, fault of stator winding and main cable may significantly increase the load of engine.
  • Page 86 Diesel Gen-set Operation Instructions machine oil is great due to too much machine oil level in oil pan between machine oil in oil pan. high and low levels of dipstick. Exhaust gas turbocharger is blocked or Clean exhaust gas turbocharger, and impeller is damaged.
  • Page 87 Diesel Gen-set Operation Instructions The diesel engine hasn’t been warmed up before Remove the load, switch on increasing the load, so knocking sound is made due and load the Gen-set after it to too big clearance between piston and cylinder changes into hot state in idle liner.
  • Page 88 Diesel Gen-set Operation Instructions Contact with after-sales service Fault of governor personnel for repair. 4. Overspeed of engine Serial Cause Elimination method number Damage to injection pump plunger or delivery valve seat, deformation of plunger bushing due to too large tightening torque, impurity in clearance of plunger pair, too Contact with after-sales service personnel thin gasket on positioning bolt of plunger...
  • Page 89 Diesel Gen-set Operation Instructions controller, oil pressure sensor replace them if necessary. Machine oil is insufficient. Fill machine oil. Viscosity of machine oil decreases due to high temperature, which reduces oil Clean cooling system and oil cooler. pressure. Leakage of lubricating oil circuit of diesel Replace the leaking part.
  • Page 90 Diesel Gen-set Operation Instructions Find out the leaking point for repair and Oil supply system leaks. replacement. Contact with after-sales service personnel Fault of injection pump to recalibrate or replace. 8. Lubricating oil consumption is too high Serial Cause Elimination method number Wrong lubricating oil trademark Use lubricating oil of correct trademark.

  • Page 91: Chapter 11 Service Commitment

    Chapter 11 Service Commitment Dear users: Welcome to use Weichai products! Thank you for your favor of Weichai products! In order for correct use and maintenance of the Gen-set, please carefully read instructions for use and maintenance, and operate in strict accordance with relevant provisions.

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