WEICHAI WPG13.5 User manual

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

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.
Please refer to and read diesel engine’s operation manual, alternator’s user
manual and drawings and documents of control part, etc. provided with the Gen-set
whiling reading this manual, in order to prevent accidental operations and
misjudgment on faults.
Precautions in this manual are basic principles that the operators must follow
and perform strictly. The purpose of safe and effective operation can be realized only
if the equipment is operated and maintained correctly. Occurrence of many accidental
injuries often is caused by the reason that basic safety rules are not observed.

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. ENVIRONMENT ADAPTABILITY OF THE GEN-SET .......................... 6
IV. POWER CORRECTION OF THE GEN-SET ............................................. 6
V. RANGE OF APPLICATION ......................................................................... 7
CHAPTER 3 OVERVIEW ON MAIN STRUCTURE OF THE GEN-SET ................ 8
I. DIESEL ENGINE ........................................................................................... 8
II. ALTERNATOR.............................................................................................. 8
III. CONTROL PANEL.................................................................................... 16
CHAPTER 4 MAIN SPECIFICATIONS AND TECHNICAL PARAMETERS OF
THE GEN-SET ........................................................................................................... 28
CHAPTER 5 TRANSPORTATION OF THE GEN-SET ........................................... 31
CHAPTER 6 INSTALLATION OF THE GEN-SET ................................................. 32
I. PREPARATIONS BEFORE INSTALLATION............................................ 32
II. REQUIREMENTS FOR INSTALLATION OF THE GEN-SET................ 32
III. STANDARD EQUIPMENT ROOM ARRANGEMENT OF THE
GEN-SET................................................................................................................ 42
CHAPTER 7 COMMISSIONING OF THE GEN-SET ............................................. 43

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 ........................... 60
I. MAINTENANCE AND CARE SCHEDULE .............................................. 60
II. MAINTENANCE AND CARE OPERATION ........................................... 61
CHAPTER 10 COMMON FAILURES AND TROUBLESHOOTING..................... 72
CHAPTER 11 SERVICE COMMITMENT ............................................................... 87
I. SERVICE CONCEPT................................................................................... 87
II. SERVICE COMMITMENT ........................................................................ 87
III. PRINCIPLE AND PROVISION OF QUALITY WARRANTY (“THREE
GUARANTEES”)................................................................................................... 87

Diesel Gen-set Operation Instructions
1
Chapter 1 Safety
I. Safety rules
Before starting the Gen-set, be sure to read this Operation Manual carefully and know
this equipment well. The purpose of safe and effective operation can be realized only
if the equipment is operated and maintained correctly. Occurrence of many accidental
injuries often is caused by the reason that basic safety rules are not observed. The
Gen-set equipment must be operated only by trained electricians. The following rules
are provided to remind operators and maintenance personnel of the danger situations
that may occur:
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;
1.2 Do not open cover plate of alternator during operation of the Gen-set, or injuries
or even death may be caused by electric shock;
1.3 The air switch shall be turned to switching-off position and the Gen-set shall be
stopped when operators perform maintenance on wiring harness of the equipment, or
injuries or even death may be caused by electric shock;
1.4 Do not handle electrical failures while wearing wet clothes (especially wet shoes)
or having wet skin.
2. Fire hazard may cause injuries or even death of operators
2.1 Open flames and smoking must be prohibited in equipment room of the Gen-set.
Battery and fuel of the Gen-set are inflammable, especially lead-acid battery may
generate explosive hydrogen when being charged, and may cause personal injuries or

Diesel Gen-set Operation Instructions
2
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. Rotating parts may cause injuries or even death of operators
3.1 All rotating parts of Gen-set shall be equipped with protective cover, for example,
flywheel, fan and charging alternator, etc. shall be equipped with protective cover. In
addition, fastening condition of these rotating parts shall be inspected at a regular
interval;
3.2 Do not get close to rotating parts when wearing loose clothes because these would
be wrapped in rotating parts and cause personal injuries, or even death;
3.3 Keep your hands away from rotating parts when the Gen-set is operating.
4. High-temperature parts may cause injuries of operators
4.1 Do not open radiator cap when the Gen-set is operating or immediately after the
Gen-set is stopped, or splashed high-temperature liquid would cause injuries of
operators;
4.2 Do not try to touch exhaust pipe, turbocharger, high-temperature coolant and
other high-temperature parts of the Gen-set with your hands when the Gen-set is
operating, or your hands would be burnt;
4.3 Owing to the temperature of exhaust pipe is high and in order to prevent burns,
the pipe shall be wrapped with heat-resisting materials (e.g. glass fiber or aluminum
silicate, etc.), in order to complete thermal insulation. In addition, exhaust terminal
and exposed part of exhaust pipe shall be kept away from woods or other flammable
substances, especially the fuel piping.
II. Safety symbols

Diesel Gen-set Operation Instructions
3
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.
Table 1-1 Meanings of safety symbols used on Weichai Gen-set
No. Symbols Description
1
A warning meaning that there is some
immediate danger that may cause serious
injuries or even death if cannot be
avoided.
2
A warning meaning that there is some
potential danger that may cause serious
injuries or even death if cannot be
avoided.
3
A warning meaning that a potential risk
that may cause minor or moderate injuries
if cannot be avoided.
4 No lifting
5 No smoking
6 No switching-on
7 Beware of burns

Diesel Gen-set Operation Instructions
4
8 Beware of hot surface
9 Beware of electric shock
10 Beware of rotating parts
11 Beware of auto starting
12 Must be grounded
13 Lift up the Gen-set from here
14 Transport with a forklift from here

Diesel Gen-set Operation Instructions
5
Chapter 2 Operating Conditions and Purposes
Diesel Gen-set is a diesel-fueled small-size electro-mechanical power generation
equipment in which alternator produces electric energy under driving of diesel engine
(prime motor). It converts heat energy (combustion of diesel oil) into mechanical
energy (power inverse rotation) and electric energy (AC alternator cuts magnetic field)
finally. In this process, fuel is its raw material and electric energy is its product.
I. Description on model of the Gen-set
Model of the Gen-set consisting of four parts is named as per following rules:
II. Description on power of the Gen-set
1. Rated power: it refers to the maximum power that the Gen-set is able to provide
continuous power supply to variable loads without limitation in annual running time
between specified maintenance intervals and under specified environmental
conditions.
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.
Structure form code, ‘B’ represents common
open-type and ‘F’ represents common chassis fuel
tan
k
t
yp
e.
Series code
Reserve capacity of the Gen-set, kVA
Weichai Power Generation

Diesel Gen-set Operation Instructions
6
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.
Ambient temperature: 25℃
Range of altitude: 0~1000m
Relative air humidity: 30%~60%
Under non-standard environmental conditions, the Gen-set shall be able to operate
normally. But, rated power of the Gen-set must be corrected.
IV. Power correction of the Gen-set
When the Gen-set is going to operate under non-standard environmental conditions,
rated power of the Gen-set shall be corrected. If the load power of the Gen-set during
operation is greater than corrected rated power, the diesel engine will belch a lots of
black smoke and become overheating. If operation like this is kept for a long period
of time, diesel engine will malfunction seriously or be damaged, so this situation must
be avoided.
When ambient temperature is extremely high, air density would decrease, amount of
oxygen provided during combustion of diesel engine will decrease. As combustion
efficiency reduces and mechanical output power of diesel engine will reduce
accordingly; at the same time, winding needs to be cooled by air during operation of
alternator, thus cooling performance will decrease and internal temperature of
alternator winding will raise when ambient temperature is extremely high. Therefore,
in order to ensure that temperature of alternator winding is kept within an allowable

Diesel Gen-set Operation Instructions
7
range, output power of alternator must be reduced.
Air density will decrease also when the altitude increases, thus output of diesel engine
and alternator will be affected also.
Although output power of diesel Gen-set would not decrease when being operated
under low temperature and high humidity regions, the factors that may have an
impact on normal operation of the Gen-set under different site conditions must be
taken into consideration also during model selection.
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
At present, diesel Gen-set has been widely used in aviation, shipping, national
defense, communication, petroleum, medical treatment, mining, wild rescue,
agriculture and animal husbandry, as well as other fields to ensure reliability and
stability of power supply system.

Diesel Gen-set Operation Instructions
8
Chapter 3 Overview on Main Structure of the Gen-set
1. Inlet of fuel delivery pump 2. Silencer 3. Air filter 4. Control panel 5.
Breaker 6. Alternator 7. Ground connection 8. Absorber 9. Chassis 10.
Oil drain hole 11. Fuel level indicator 12. Forklift groove 13. Lift hook
14. Water drain of radiator 15. Water inlet of radiator 16. Radiator 17.
Batteries
Remarks: B series gen-set without fuel tank and fuel level indicator
Fig. 3-1 Structural schematic diagram of the Gen-set
The Gen-set mainly consists of diesel engine, alternator, control panel and chassis, etc.
Detail structure of the Gen-set is as shown in Figure 3-1. Main parts of the Gen-set
will be detailed below.
I. Diesel engine
Diesel engine is power source of the Gen-set. For detail structure and principles,
please refer to Diesel Engine Operation and Maintenance Manual.
II. Alternator

Diesel Gen-set Operation Instructions
9
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.
Figure 3-2 Sectional view of alternator
2. Operating principles of alternator
After alternator is driven, main stator (armature) generates certain remanence voltage,
automatic voltage regulator (AVR) outputs a remanence current to exciter stator
(magnetic field) after obtaining remanence voltage from main stator (armature),
exciter rotor (armature) generates three-phase alternating current which is then
transmitted to main rotor (magnetic field) excitation winding after being rectified into
direct current by rotary rectifier, in order to enhance magnetic field of main rotor and
increase voltage of main stator (armature). By constant cycling of this voltage buildup
process, alternator builds up rated voltage steadily in a short time.
Rotar
y
rectifie
r
Optional permanent
ma
g
net alternato
r
Coupling
Fan
Main rotor
(
ma
g
netic field
)
Main stator (armature)
Stator alternating
current output
Bearing
Permanent magnet
stator (armature)
Permanent magnet
alternator rotor
(magnetic field)
Exciter stator (magnetic
field) Exciter rotor
(armature) Installation of
coupling

Diesel Gen-set Operation Instructions
10
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.
Weichai 10-50kW Gen-set is equipped with AS440, BE350, AS480 type AVR (type
of AVR is clearly marked on nameplate of alternator). Structure and function of AVR
are described below respectively.
Permanent magnet alternator
(optional)
Permanent magnet rotor (rotor)
Permanent magnet
alternator (armature)
Excitation stator
(
ma
g
netic field
)
Rotary rectifier (three-phase
full wave rectifier)
Main rotor (magnetic
field
)
Excitation rotor
(armature)
Rotating part
Three-
p
hase alternating
current (output)
Three-
p
hase alternating
current (output)
Excitation field (direct
output)
Main stator (armature)
Input signal-single item (voltage regulator input power)
Detection input
Automatic voltage
regulator (AVR)

Diesel Gen-set Operation Instructions
11
3.1 AS440
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;
2) As shown in Figure 3-5, terminal 7 and 8 are connected to main stator (armature)
of alternator and terminal F1 and F2 are connected to exciter stator (magnetic field);
Stabilit
y
selection
Jumper
Jumpe
r
Frequency selection
LED
i
n
di
cator
li
g
h
t

Diesel Gen-set Operation Instructions
12
Figure 3-5 AS440 Wiring diagram
3) Terminal 1 and 2 are used for external connection of voltage regulator, thus they
must be short-connected if external voltage regulator is not installed;
4) Terminal La and Lb are only applicable for some special low-voltage applications;
5) When this Gen-set is connected in parallel, S1 and S2 are used for connection of
regulating current transformer and A1 and A2 are used for connection of VAr/PF
controller;
6) Stability adjustment shall be selected as per Table 3-1;
Table 3-1 Stability selection list
Serial number Power range Response speed
B-D 〈100kW Slow
A-C 〈100kW Fast
B-C 100-550kW Fast
A-B 〉550kW Fast
7) Frequency selection is as shown in Figure 3-4.
8) See Table 3-2 for roles and adjustment methods of AVR adjustment potentiometer.
N
ote:
Manual voltage potentiometer shall be equipped with twin-core
shielded wire connecting to alternator casing or being
grounded directly.
Output terminal
Regulating current
transformer
Stator winding
Manual voltage
potentiometer
Low voltage mode
AVR input terminal
Main stator (armature)
Main rotor (magnetic field)
Excitation stator
Excitation rotor
Rotary rectifier

Diesel Gen-set Operation Instructions
13
Table 3-2 Function list of AS440 adjustment potentiometer
No. in
figure Control button Function Direction of adjustment
1 Voltage
Adjust output voltage of
alternator
Turn clockwise to
increase output voltage
2 Droop (applicable for
parallel connection)
Droop is 5% when power
factor of Gen-set is 0
Turn clockwise to
increase droop
3 Fine adjustment Increase analog input
sensitivity
Turn clockwise to
increase gain or
sensitivity
4 Over-excitation tripping Set over-excitation tripping
trigger potential
Turn clockwise to
increase tripping trigger
potential
5 Stability Prevent voltage swing Turn clockwise to
increase damping effect
6
UFRO
(Under-Frequency Roll
Off)
Set UFRO knee point
Turn clockwise to
decrease knee point
frequency
3.2 BE350
Figure 3-6 BE350 wiring diagram
N
otes:
For remote adjustment, use a
2Kohm and 0.5W potentiometer
(adjustment range is up to 10%).
For 50Hz alternator, its frequency
j
umper shall be moved to 50Hz
terminal.

Diesel Gen-set Operation Instructions
14
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 21Ωand 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;
2) Excitation winding and regulator of exciter obtain power from output end of
alternator. The acceptable power input range is 171~264Vac and power input is
connected to terminal 3 and 4.
3.3 AS480
Figure 3-7 AS480 structure and wiring diagram
1) Terminal 7 and 8 are connected to main stator (armature) of alternator and terminal
F1 and F2 are connected to stator (magnetic field) of exciter.
2) Terminal 1 and 2 are used for external connection of voltage regulator, thus they
must be short-connected if external voltage regulator is not installed;
3) When this Gen-set is connected in parallel, S1 and S2 are used for connection of
regulating current transformer;
Connection of excitation gain
startin
g
s
y
stem
(
EBS
)
Slow
Connecti
on BC
No
connectio
n
Rise
Manual trimmer
(
o
p
tional
)
Droop C/T (optional)
Remove connection
before installation
Slow
Connecti
on BD
Stability connection
UFRO connection

Diesel Gen-set Operation Instructions
15
4) Stability adjustment shall be selected as per Table 3-3.
Table 3-3 Stability selection list
Serial number Power range Response speed
B-D 〈100kW Slow
No connection 〈100kW Fast
B-C 〉100kW Fast
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 Direction of adjustment
Voltage Adjust output voltage of
alternator
Turn clockwise to
increase output voltage
Droop (applicable for
parallel connection)
Droop is 5% when power
factor of Gen-set is Gen-set
as 0
Turn clockwise to
increase droop
Stability Prevent voltage swing Turn clockwise to
increase damping effect
UFRO (Under-Frequency
Roll Off) Set UFRO knee point
Turn clockwise to
decrease knee point
frequency
3.4 Regulating method of AVR
Adjustment potentiometer on AVR has been set when being delivered from factory, so
it is unnecessary to adjust other buttons at random except voltage and stability button.
1) Adjustment method of voltage
Counterclockwise turn voltage adjustment button on AVR to the end, then place this
regulator knob to middle position if the alternator is provided with an external voltage
regulator. Start Gen-set and slowly turn voltage regulator on AVR clockwise under
Rated speed until rated voltage is reached.
2) Adjustment method of voltage stability
When adjustment is necessary for the reason of unstable voltage, following operation

Diesel Gen-set Operation Instructions
16
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).
III. Control panel
Control panel is “brain” of the Gen-set as it not only enables starting, stopping, data
measurement, data display and fault protection of engine, but also enables electricity
measurement, electricity display and electricity protection, etc. of alternator. The
control panel of DSE6020 module or DSE7320 module can be provided with
mechanically governing or electronically governing diesel engine. Structure of the
control panel of DSE6020 module is as shown in Figure 3-8.
DSE6020 module
Power switch
Door lock
Emergency stop button
Air switch