WhisperPower W-SQ 6 User manual

USERS MANUAL FOR MOBILE APPLICATIONS
W-SQ6
- 1500 RPM -
Mobile diesel generating set 230V / 50Hz
Digital Diesel Control
WHISPER POWER BV
Kelvinlaan 82
9207 JB Drachten
The Netherlands
Tel.: [phone]
Fax.: [phone]
www.whisperpower.eu
V1 October 2008
Art.nr. 40200131

CONTENTS
2 October 2008 / W-SQ6 for mobile applications / EN
CONTENTS:
1 INTRODUCTION.............................................................................................................................................................. 4
1.1 General ..............................................................................................................................................................4
1.2 Service and maintenance...................................................................................................................................4
1.3 Guarantee ..........................................................................................................................................................4
1.4 Liability...............................................................................................................................................................5
1.5 Identification.......................................................................................................................................................5
1.5.1 General.............................................................................................................................................. 5
1.5.2 Identification plate..............................................................................................................................6
2 INFORMATION................................................................................................................................................................ 7
2.1 Safety................................................................................................................................................................. 7
2.1.1 General.............................................................................................................................................. 7
2.1.2 Electrical safety.................................................................................................................................7
2.1.3 Earth insulation failures..................................................................................................................... 7
2.1.4 Installation.........................................................................................................................................7
2.1.5 Operation........................................................................................................................................... 8
2.1.6 Fire and explosion............................................................................................................................. 8
2.1.7 Chemicals.......................................................................................................................................... 8
2.2 Transport, lifting and storage..............................................................................................................................9
2.3 W-SQ6 ...............................................................................................................................................................9
2.3.1 Features............................................................................................................................................9
2.3.2 Remote 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
2.5.10 Fuel specification............................................................................................................................. 13
2.5.11 Oil information ................................................................................................................................. 13
2.5.12 Cooling liquid................................................................................................................................... 13
2.5.13 Technical data................................................................................................................................. 14
2.5.14 Wiring codes and colours................................................................................................................15
2.5.15 Lay outs control wiring..................................................................................................................... 16
2.5.16 Electrical diagrams 230 V AC / 50 Hz.............................................................................................. 19
2.5.17 Electrical diagrams radiator fan control ........................................................................................... 20
2.5.18 Diagram electronic governor (optional)............................................................................................ 22

CONTENTS
EN / W-SQ6 for mobile applications / October 2008 3
3 OPERATION.................................................................................................................................................................. 23
3.1 General ............................................................................................................................................................ 23
3.2 Operating Instructions ...................................................................................................................................... 23
3.2.1 Summarised operating instructions (daily use)................................................................................ 23
3.2.2 Extended operating instructions...................................................................................................... 23
4 MAINTENANCE............................................................................................................................................................. 25
4.1 Alternator.......................................................................................................................................................... 25
4.2 Engine.............................................................................................................................................................. 25
4.2.1 Preliminary instructions ................................................................................................................... 25
4.2.2 Bleeding fuel lines ........................................................................................................................... 25
4.2.3 Valve clearance............................................................................................................................... 25
4.2.4 Replacing fuel filter.......................................................................................................................... 25
4.2.5 Replacing oil filter............................................................................................................................ 25
4.2.6 Readjustment V-beltplacing oil filter ................................................................................................ 26
4.2.7 Air strainer element ......................................................................................................................... 26
4.3 Regular maintenance....................................................................................................................................... 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 ................................................................................ 33
5.3.2 Testing rotary rectifier diodes .......................................................................................................... 33
5.3.3 Winding resistant values.................................................................................................................. 33
5.3.4 Meggering ....................................................................................................................................... 33
5.4 Special procedures engine............................................................................................................................... 34
5.4.1 Setting the RPM .............................................................................................................................. 34
5.4.2 Adjusting valve clearance and retightening the cylinder head bolts................................................. 34
5.4.3 Disassembling instructions.............................................................................................................. 35
6 SPARE PARTS LIST ..................................................................................................................................................... 36
MAINTENANCE LOG ............................................................................................................................................................... 38

INTRODUCTION
4 October 2008 / W-SQ6 for mobile applications / EN
1 INTRODUCTION
1.1 GENERAL
The W-SQ6 Mobile Diesel Generating set is manufactured
and marketed by Whisper Power.
It is important to read this manual before installing and
operating the generating set. Both safety and durability
rely very much on the correct identification, installation and
a good understanding of ratings, features, design,
maintenance and operation procedures.
The information, specifications, illustrations and
statements contained within this publication are given with
our best intentions and are believed to be correct at the
time of going to press.
All of the specifications, provisions and instructions
contained in this manual apply solely to standard versions
of the Whisper Power W-SQ6 generating set.
This manual is valid for the following models:
Part number Description
41105020 W-SQ6 230V 1500rpm
Mobile / keel cooling
41105026 W-SQ6 230V 1500rpm
Mobile / keel cooling -ungrounded
For other models see other manuals available on our
website: www.whisperpower.eu
Our policy is one of continued development and we re-
serve the right to amend any technical information without
prior notice.
Whilst every effort is made to ensure the accuracy of the
particulars contained within this publication neither the
manufacturer, distributor, or dealer in any circumstances
shall be held liable for any inaccuracy 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 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 on the vehicle.
1.2 SERVICE AND MAINTENANCE
Regular service and maintenance should be carried out
according to the directions in this manual. For service and
maintenance one can appeal to the manufacturer or the
dealers.
1.3 GUARANTEE
Whisper Power guarantees that this generating set has
been built according to good workmanship, according to
the specifications in this manual and according to
European Community safety regulations.
During production and prior to delivery, all of our
generating sets are tested and inspected.
The well functioning of this generating set is subject to
guarantee. The period and conditions of this guarantee are
laid down in the general conditions of delivery as
registered with the Chamber of Commerce and Industries
for the North of the Netherlands number 01120025 and
are available on request. The guarantee period is two
years, limited to 1000 running hours. Some aspects of our
guarantee scheme are given here in more detail:
Guarantee does not cover failures that are caused by
misuse, neglect or a faulty installation.
Example 1. Faulty installation:
Overheating of the engine or alternator is the most
common cause of problems with mobile generating sets.
These problems are caused by poor circulation of the
cooling liquid due to wrong routing of the pipes to the
radiator: bents will capture air bubbles causing “air-lockes”
blocking the circulation of the liquid. Other examples of
installation problems are hot air circulation into the radiator
and the radiator fan sucking exhaust gasses into the
radiators.

INTRODUCTION
EN / W-SQ6 for mobile applications / October 2008 5
The generator and other parts should be protected against
the influences of the weather and splashing water (with dirt
and salt) below the vehicle. Refer to the installation
manual for instructions but remember these are for
guidance only as many factors influence the installation of
a generator. The ultimate responsibility will always be with
the owner to ensure a safe and compliant installation. If in
doubt ask!
Example 2: Misuse:
Long term running with no load or too little load can cause
the exhaust to get choked with soot or carbon. Cleaning
the exhaust is not covered by guarantee.
Example 3: Neglect
Whisper generators have an option for an auto start/stop
mode or interval mode.
Whisper Power cannot be held responsible for damage
caused by the unattended running generator.
Guarantee means that faulty parts are repaired or
replaced free of charge. If necessary the whole generator
unit will be exchanged. Labour necessary to complete
repairs on board a vehicle executed by an authorized
service engineer is covered, but is limited to a reasonable
number of hours and reasonable rates in relation to the
actual repair work that has to be done.
Travel expenses and travel hours are not covered. Also
not covered is the labour required to take a generator out
of a vehicle or for reinstallation. There is no cover for
labour needed to get access to the generator, for example
to remove equipment or parts of the vehicle body etc.
Goods to be delivered under guarantee will 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 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 normal carriage will be
invoiced to the customer.
The cost for returning faulty goods is not covered under
guarantee.
If any problem arises which could be subject of guarantee,
procedures should be followed as described in the
guarantee conditions, unauthorised repairs could lead to
further damage and violate the guarantee conditions.
Should work take place, which is not in
accordance with the guidelines, instructions
and specifications contained in this user’s
manual and the supplementary installation
manual, then damage may occur and the
generating set may not fulfil its specifications.
In all these cases the guarantee may become
invalid. Use original spareparts only!
1.4 LIABILITY
Whisper Power does not accept responsibility for damage,
injuries or casualties which are the result of operation of
the generating set in specific conditions which brings
dangers which could not be foreseen, or could be avoided
by additional measures. Whisper Power does not accept
liability for damage due to use of the generator, possible
errors in the manuals and the results thereof.
Automatic start/stop
Whisper Power cannot be held responsible for
damage caused by the unattended running generator
using the auto-start/stop mode or interval mode.
1.5 IDENTIFICATION
1.5.1 General
Before using this generating set it is very important to
identify the set correctly. To communicate for service or
ordering parts it is also essential to correctly identify the
generating set. Also for the daily operation of the genera-
ting set it is necessary that the operator knows the correct
specifications.

INTRODUCTION
6 October 2008 / W-SQ6 for mobile applications / EN
1.5.2 Identification plate
All required identification data are on the identification
plate. For location of the identification plate see figure 1.
Fig. 1: Location identification plate.
1 The identity of the generating set is given by the
SERIAL NUMBER.
When this number is available the manufacturer can
trace the specifications of the generating set. On the
identification plate are also some basic features of the
set:
2 POWER
The identification plate gives the nominal maximum
continues load in kVA (= kW) calculated with power
factor one. When calculating a load one should
always take into account the power factor or cos phi
of this load. The power should never exceed the
nominal power as shown on the identification plate.
Power is rated at an ambient temperature of 25ºC.
For higher temperatures the generating set has to be
derated. To drive the radiator fan (230 V fan) output
could be taken from power generated by the genset.
In that case net power will be 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
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 weight (approximately) in
kg. This is without fuel, oil, cooling liquid, packing and
external installation equipment
7 CE-marking: the “CE” symbol shows that the
generating set is build according to European
Community safety regulations. This includes the
regulations regarding the safety of pleasure craft,
safety of machinery, electric safety and electric
magnetic compatibility (EMC) and other relevant
directives.
Safety also relies on the installation, application and
circumstances. See also the remarks in this manual under
SAFETY
Before changing a factory setting you are advised to
consult the manufacturer. When the generating set you
have to identify is not new you have to take into account
the possibility that former users may have changed the
settings. Check the settings (voltage, frequency, rpm)
when there is any doubt.

INFORMATION
EN / W-SQ6 for mobile applications / October 2008 7
2 INFORMATION
2.1 SAFETY
2.1.1 General
When correctly installed and used in normal
circumstances this generating set fulfils EC safety
regulations. This generating set could be part of an
installation or could be used in a way that additional
regulations of the EC or other authorities have to be taken
into account.
Circumstances could make it also necessary
to take additional measures. Be aware of wet
conditions and hazardous environments
caused by explosive gases etc
2.1.2 Electrical safety
The voltage of 230 Volt generated by this
generating set is dangerous and if instructions
and procedures are not strictly observed may
result in electrical shock which will result in
severe personal injury or loss of life.
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 on the vehicle.
•Check all wiring at least once a year. Defects,
such as loose connections, burned cables etc.
must be repaired immediately.
•Do not work on the electrical system if it is still
connected to a current source. Only allow
changes in your electrical system to be carried
out by qualified electricians.
•Connection and protection must be done in
accordance with local standards.
•Using the 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 measures for
protection against earth insulation failures.
In the standard delivery “neutral” and “ground” are not
connected. To make a connection between “neutral” and
“ground” could be necessary as part of a specific
insulation failure protection system.
In all situations the transfer switches between
shore, inverter and generator should switch
both neutral and L1. Of course this is the case
when using a Mastervolt Mass Systemswitch.
2.1.4 Installation
Whisper generating sets are not self contained and have
to be properly installed in enclosed areas. Installation
includes measures to be taken to outlet exhaust fumes
which contain carbon monoxide and are extremely
dangerous. Carbon monoxide (CO) is an invisible
odourless gas. Inhalation produces headache, nausea or
death. Installation includes measures for proper
ventilation, safe electric connections, safe installation of
the starting battery, proper fitting of the cooling system and
fuel pipes etc. Refer to the installation manual.
Do not use the generator set when the vehicle
is inside a building or in other enclosed area’s.
Be aware using the generator in wind still
conditions, when the exhaust fumes could
accumulate under, around or even in the
vehicle.

INFORMATION
8 October 2008 / W-SQ6 for mobile applications / EN
2.1.5 Operation
External moving parts like fans and V-belts are covered by
the soundshield and therefore the W-SQ6 is very safe
when the soundshield is closed.
Nevertheless take note of the signs on the
generating set which show symbols in a
triangle indicating danger.
When service has to be carried out while the
engine is running, be aware of moving parts
like V-belts.
•The generating set should be operated by
authorised personnel only.
•Be aware of hot parts and especially parts of the
exhaust system and the cooling system.
•If the generating set is unsafe, fit danger notices
and disconnect the battery positive (+) lead so
that it cannot be started until the condition is
corrected.
•Do not attempt to operate the generating set with
a known unsafe condition. Disconnect the battery
positive (+) lead prior to attempting any repairs or
cleaning inside the enclosure.
•Always consult the manual before carrying out
maintenance.
•Do not change the settings without consulting the
manufacturer. Keep a record of setting changes
in this manual.
2.1.6 Fire and explosion
Fuels can be flammable. Proper handling
limits the risk of fire and explosion.
•Avoid refilling the fuel tank while the engine is
running. When oil or fuel is leaking do not use the
generating set.
•Do not run the engine close to explosives or
gasses.
•Hydrogen gas generated by charging batteries is
explosive. Ensure for proper ventilation. Do not
smoke or allow sparks, flames, or other sources
of ignition around batteries.
•Keep a fire extinguisher on hand.
INCASEOFFIRE, DONOTOPENSOUNDSHIELD.
TOAVOIDSERIOUSINJURYORDEATHFROMFIRE
IMMEDIATELYDISCHARGEENTIRECONTENTSOFGASEOUS
SHUTDOWNENGINES, GENERATORSETSANDBLOWERS.
PORTABLEFIREEXTINGUISHERTHROUGHTHISPORT.
THROUGH
HERE
FIREEXTINGUISHERPORT:
BREAK
Fig. 2: Fire extinguisher port.
•In case of fire do not open the soundshield. To
avoid serious injury or death from fire, shut down
engines, generator sets and blowers. Break
through the label which is indicated by BREAK
THROUGH HERE and then immediately
discharge entire contents of gaseous portable fire
extinguisher through the fire extinguisher port. On
the generating set this fire extinguisher port is
indicated by the label as shown in figure 2.
•Poor electrical connections or using wiring which
is not suited for the rated currents can cause
overheating and possibly fire.
2.1.7 Chemicals
•Fuels, oils, coolants, and battery electrolyte can
be hazardous to personnel if not treated properly.
Do not swallow or have skin contact with these
liquids. Do not wear clothing that has been
contaminated by fuel or lubricating oil.
•Gaskets may be manufactured from asbestos.
Particles of this material should not be inhaled as
this may result in fatal diseases.
•On no account allow any unprotected skin to
come into contact with the injector spray as the
fuel may enter the blood stream with fatal results.
•Engines may be fitted with seals or O-rings
manufactured from "viton" or similar material.
When exposed to abnormal high temperatures in
excess of 400°C an extremely corrosive acid is
produced which cannot be removed from the

INFORMATION
EN / W-SQ6 for mobile applications / October 2008 9
skin. If signs of decomposition are evident, or if in
doubt, always wear disposable heavy duty
gloves.
2.2 TRANSPORT, LIFTING AND STORAGE
When lifting the generating set avoid any risk
of personal injuries, do not stand under the
generating set.
•Use soft slings to avoid damage
•On the engine are two hoist eyes which can be
used to take the generator out of the capsule.
They can also be used to lift the complete
generating set including the capsule.
•After transporting the generating set check for
damage before installation.
•Long term storage can have detrimental effects
on engine and alternator. The engine should be
put through an engine preservation procedure.
(Refer to the maintenance chapter)
•The alternator windings tend to condense. To
minimise condensation, store the generating set
in a dry and warm storage area.
•After removing the generating set from long term
storage perform an insulation check. (Refer to the
alternator maintenance paragraph for
procedures)
•While the battery is stored it should be recharged
every 12 weeks.
2.3 W-SQ6
2.3.1 Features
This generating set includes 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 materials.
Installation accessories are listed in the installation manual
and are available through the supplier of the generating
set. The full automatic Digital Control is based on
microprocessor technology. Several automatic start/stop
functions can be programmed and monitored (refer to
Digital Diesel Control users manual).
2.3.2 Remote control
The full automatic remote control panel including 15 mtr
cable comes as standard with the Whisper generating set.
2.3.3 Documentation
Included in the delivery are:
•This users manual (number: 40200131)
•An installation manual (number: 40200241)
•A users manual for DCC (number: 50200261).
•A quick reference guide for DDC (number
50200275)
Not included in the standard delivery but available as
options are:
•Parts manual; number: 40200182
•Workshop manual; number: 40200171
However in this manual there is a list of important parts for
maintenance and spare parts as well as a chapter on
maintenance and problem solving.

INFORMATION
10 October 2008 / W-SQ6 for mobile applications / EN
2.4 COMPONENTS
2.4.1 Main components to identify
Fig. 3 Front View main components W-SQ6
Fig. 4: Front view main components W-SQ6
01 Fuel injection pump
02 Fuel injector (3x)
03 Glow plug (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 lift pump
21 Engine oil filter

INFORMATION
EN / W-SQ6 for mobile applications / October 2008 11
Fig. 5: Rear view main components W-SQ6
Fig. 6: Rear View main components W-SQ6
45 Temperature switch
46 Thermostat housing
47 Filler cap engine oil
48 Filler cap engine coolant
49 Rocker cover
50 Hoist eye rear
51 Expansion tank
52 AC Generator
53 Exhaust 1½”
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 V-belt
39 Engine coolant pump
41 Exhaust manifold (water-
cooled)

INFORMATION
12 October 2008 / W-SQ6 for mobile applications / EN
2.4.2 Generator control panel
Start/ Stop
Removefuse
Internal fuel pump
Fuse3A
beforemaintenance
Digital Diesel Control
Fuse3A
Auxiliary
Fuse10A External Fuel Pump Fuse3A
Observeinstructionsinthemanual
Replace fuseswithsametype andrating
Whisper Digital Diesel OperationUnit
Fig: 7 Control panel.
Fig. 8 Digital Diesel Control unit
2.4.3 Remote control panel
04
03
02
01
05 07 06
01 Generator load indicator
02 Failure LED
03 Start button
04 Stop button
05 Display
06 Select button
07 Set button
Fig. 9: Digital Diesel remote control panel
2.5 TECHNICAL INFORMATION
2.5.1 AC alternator
The single phase alternator is directly coupled, one
bearing, brushless, rotating field design, four poles (1500
RPM) and self regulating.
Residual magnetism causes a small voltage over the
stator windings and allows a current to flow in the
windings, which is magnified because of the feed back
effect between rotor and stator. The field windings in the
rotor are short-circuited over a diode to rectify the current.
A capacitor over an additional winding in the stator which
is at an angle with the power-winding keeps the voltage
stable within 5 % at the specified rpm and provides voltage
fall off with speed, preventing 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-SQ6 generating set is based on the Mitsubishi L3E
3 cylinder diesel engine. The engine is indirectly injected.
The engine is water cooled and the cooling liquid is cooled
by a radiator.
The engine has been specially adapted for the Whisper
Power application and is very different from the standard
engine supplied for industrial applications!
2.5.3 Digital Diesel Control system
The standard electrical engine control system is 12 Volt
negative earth, non earth return (ungrounded) is available
as option. Check your identification data to determine
which system is applied. The system is designed
according to the "energise to run" system. The Digital
Diesel Control is a very advanced microprocessor based
full automatic system. Besides automatic start the system
offers many monitoring options. Refer to the separate
Digital Diesel Control users manual.
The microprocessor unit is located in the black box on top
of the alternator
2.5.4 Battery charger
On the engine is an alternator generating 40 Amp 12V.
This current is rectified to charge the battery. The voltage
is regulated at ±14.4V.
2.5.5 Alarms and shut down
In the event of malfunctioning this will be indicated by the
failure light, details will be shown on the display and the
engine will be shut down. There are three functions

INFORMATION
EN / W-SQ6 for mobile applications / October 2008 13
guarded: oil pressure, coolant temperature and alternator
temperature.
Too high alternator temperature indicates the alternator
coolant to be blocked or the pump impeller to be
damaged.
All alarm switches are closed when no malfunction occurs.
A contact is cut in the event of an alarm. This means that
the generating set will not work when the alarm switches
are broken or there is a loose wire. The system therefore
is intrinsically safe. The panel will display details about the
alarm.
2.5.6 Control
The generating set can be operated by push buttons on
the panel on the alternator or by the remote control. By
pushing the START button the control system is activated
and will start the engine automatically. Pushing the STOP
button will stop the engine and the electrical system will be
deactivated.
2.5.7 Remote control
All wiring connections from the remote control to the board
are made by plug in connectors.
An intermediate communication cable is in the standard
supply. If necessary an optional longer 8 wire
communication cable can be connected if the standard
length does not suit the required distance. Numerous
remote control units 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 specification
The engine must only be used with diesel fuel oil which
conforms to the standards for use in modern diesel
engines. Fuel free from water and contaminants is of the
utmost importance.
2.5.11 Oil information
1 Specification:
The oil must be suitable for oil changes as specified in
the maintenance chapter. The Mitsubishi engine must
be run on heavy duty lubricating oil meeting the
requirements 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:
Excluding the oil filter the content of the crankcase is
3.6 l. Including the oil filter it is 4.1 l.
Do not overfill with lubricating oil as this may have a
detrimental effect on engine performance
4 Oil pressure
•Minimum at idle 98 Kpa (1 kgf/cm2 - 14psi) (1
bar).
•Normal at 1500 rpm ±250 Kpa (2.5 kgf/cm2 - 35
71 psi) (2.5 bar).
2.5.12 Cooling liquid
Both the engine and alternator are cooled by cooling
liquid. The capacity of both systems depend on the size of
the radiator piping and other parts in the cooling system
We recommend not using water but cooling liquid that is
marketed for the use in combustion engines. Cooling liquid
protects the engine against frost to minus 25° C. Also it
protects the engine block against corrosion. Initially one
can fill the engine via the filling cap on the exhaust
manifold. Fill up till the level is just below the filling cap.
Filling of the alternator cooling system and additional filling
of engine cooling system has to be done via the expansion
tanks. When the engine is on temperature the liquid will
expand and the redundant liquid will be pressed into the
expansion tank. This tank has to be filled up till the mark.
On the tank is an overflow connection. This connection
can be used to connect an open hose to drain the overflow
of the cooling liquid to outside the vehicle.
When cooling liquid is not available clean fresh water
could be used with an additive of anti freeze. When using
water with anti freeze the right mixture has to be
calculated according to the information of the supplier of
the anti freeze.
The cooling liquid in the engine is pressurised. A high
pressure hose connects the manifold to the expansion
tank. The cooling liquid in the alternator is not pressurised.
The alternator’s expansion tank has an open connection to
drain liquid and release air

INFORMATION
14 October 2008 / W-SQ6 for mobile applications / EN
2.5.13 Technical data
GENERAL
Model W-SQ6
RPM 1500
Alternator water cooled, synchronous
Engine Mitsubishi diesel, model L3E
Number of cylinders 3
Displacement 952 cm3
Bore X stroke 76x70 mm
Combustion air consumption 0.9 m3/min.
Continuous power engine 5.7 kW
Cooling system By means of a radiator.
Fuel lift pump engine electric pump (12 V DC), additional pump available upon request
Starting battery (optional) 60-90 Ah 12V
Fuel consumption 1.5-2.5 litre/hour, load dependent
Control Digital Diesel Control including automatic start/stop
ELECTRICAL SPECIFICATIONS
Output voltage 230V 50 Hz alternating current (AC) single phase
Output rating 5kVA = 5kW at powerfactor 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 vibration mounts. (Generator
set without sound shield is optional)
Dimensions hxwxd 80.5 x 52.5 x 58.0 cm
Colour metallic silver / grey
Weight 240kg including sound shield
Max. installation angle 25 degrees
Standard supplies Digital remote panel (+15 m cable), fuel filter, fuel lift pump, user and installation
manuals
Available as option: Installation kits, non earth return (ungrounded), spare part kits

INFORMATION
EN / W-SQ6 for mobile applications / October 2008 15
2.5.14 Wiring codes and colours
number colour cable code no
cross section
battery > starter motor red 25 mm2
starter motor > DCC 1 red 6 mm2
starter motor > LCP 13 red 2,5 mm2
battery > ground black 25 mm2
ground > LCP ground (GND) 2 black 2,5 mm2
DDC > glow plug 3 brown 4 mm2
DDC > starter solenoid 4 yellow 2,5 mm2
LCP > fuel lift pump + 5 grey 1,5 mm2
LCP > fuel lift pump – 15 black 1,5 mm2
DDC > LCD 5 grey 1,5 mm2
DDC > oil pressure switch 6 purple 1 mm2
LCP > oil pressure switch 6 purple/black 1 mm2
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 terminal alternator 19 orange 1,5 mm2
DDC > current measuring transformer 11 black 1 mm2
DDC > current measuring transformer 11 red 1 mm2
DDC > LCP 12 black 1,5 mm2
DDC > LCP 14 red 1,5 mm2
DDC > LCP 16 red/green 1,5 mm2
DDC > generator AC output 33 brown 1 mm2
DDC > generator AC output 33 blue 1 mm2
DDC=Digital Diesel Control Unit
LCP=Local Control Panel

INFORMATION
16 October 2008 / W-SQ6 for mobile applications / EN
2.5.15 Lay outs control wiring
Fig 10: Electrical Diagram control wiring W-SQ6, using a 230V AC radiator fan
Optional control for two speeds fans. See chapter 2.5.17

INFORMATION
EN / W-SQ6 for mobile applications / October 2008 17
Fig 11: Electrical Diagram control wiring W-SQ6, using a 24V DC radiator fan

INFORMATION
18 October 2008 / W-SQ6 for mobile applications / EN
Fig 12: Electrical Diagram control wiring W-SQ6, using a 12V DC radiator fan

INFORMATION
EN / W-SQ6 for mobile applications / October 2008 19
2.5.16 Electrical diagrams 230 V AC / 50 Hz
Fig. 13: Electrical diagram 230V
EARTH AND NEUTRAL CONNECTED
EARTH AND NEUTRAL NOT CONNECTED
L1
PE
N
DDC/AC-1
230V / 50Hz
ROTOR
EXCITATION
WINDING
MAIN WINDING
MAIN WINDING
STATOR
CAPACITOR
DDC/ct-1
YELLOW/GREEN
BLACK (4)
RED (3)
BLACK (4)
RED (3)
GREEN (1)
GREEN (2)
RED (11) BLACK (11)
BROWN
YELLOW/GREEN
BLUE
BLUE (33)
BROWN (33)

INFORMATION
20 October 2008 / W-SQ6 for mobile applications / EN
2.5.17 Electrical diagrams radiator fan control
TERMINAL BLOCK
GENERATOR CONTACT PUMP (PCB)
THERMOSTAT GENERATOR THERMOSTAT ENGINE
RADIATOR COOLER
GENERATOR
BATTERY
230VAC
ENGINE RADIATOR COOLER GENERATOR
12VDC
M
230VAC
M
230VAC
5A
16
CU1,5
+
1
-
2
CU0,75
80-70?C
CU0,75
45-35?C
CU0,75
6
-
3
5A
4 5 87
CU1,5
230VAC
CU1.5
6,3A
11
6,3A
12 1413 15
5A
CU1.5
DIMENTION BOX: 270x270x180 MM
JUNCTION BOX AIR FANS
12VDC K1 K2
230/115VAC
200VA
TRAFO
230VAC
Fig. 15: 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
78
13 14
11
14
23
K2
K1
K2
K1
BAT.
+12V
PUMP
+12V GENERATOR
230VAC (L1)
K1
BAT.
–12V
GENERATOR
230VAC (N)
230VAC 230VAC
45-35°C80-70°C
THERMOSTAT COOLER
ENGINE GENERATOR RADIATOR COOLER
ENGINE
RADIATOR COOLER
GENERATOR
K2
12
A2A2
A1 A1
11
11
14
14
12
41
41
42
44
44
230V
120V
115V
110V
0
0
TRANSFORMER
230V/115VAC
200VA
400V
M M
GENERATOR
L1
N
MAIN CIRCUIT
BREAKER
AC LOAD
CIRCUIT
BREAKER
AIR FANS
6A
Fig. 14: Electrical diagram for standard fan control
using 230V AC radiator fans