Stephill 50 0 Kva Perkins Super Silent Diesel Generator 1500rpm238255
Stephill 50 0 Kva Perkins Super Silent Diesel Generator 1500rpm238255
DO NOT OPERATE THE GENERATOR BEFORE READING THIS MANUAL AND ENGINE
MANUFACTURER’S OWNER’S MANUAL AND WARNINGS.
THIS STEPHILL GENERATOR HAS BEEN DESIGNED TO PROVIDE SAFE AND EFFICIENT SERVICE IF
OPERATED AND MAINTAINED CORRECTLY.
Issue 4
Section CONTENTS Page
1.0 SPECIFICATION 1
2.0 GENERAL SAFETY 1
2.1 Warning signs 1
2.2 Safety hazards 1
3.0 POTENTIAL HAZARDS 1
3.1 Auxiliary power 1
3.2 Operating environment 2
3.3 Temperature range 2
3.4 Reference relative humidity 2
3.5 Reference barometric pressure 2
3.6 Flammable environment 2
3.7 Saline environment 2
4.0 SAFETY CONSIDERATIONS 2
4.1 General 2
4.2 Fuel 2
4.3 Bunded tank 2
4.4 Lubricating oil 2
4.5 Safe lifting 2
4.6 Earth connection 3
4.7 Fumes 3
4.8 Noise 3
4.9 Battery acid 3
4.10 Fire 3
4.11 Hot parts 3
5.0 OPERATING INSTRUCTIONS 3
5.1 Pre-Start checks 3
5.2 Emergency stop 3
5.3 Three way valve 3
5.4 Fuel lift pump priming 3
5.5 Control panel 3-4
5.6 Variable RCD ELR-3C 4
5.7 Hard wire terminals 4
5.8 Remote start terminals 4
5.9 Long term storage 5
6.0 DEEP SEA 6110 OPERATING INSTRUCTIONS 5
6.1 Controls 5-7
6.2 Viewing the instrument pages 7
6.2.1 Status 8
6.2.2 Generator locked out 8
6.2.3 Engine 8
6.2.4 Generator 8-9
6.2.5 Alarms 9
6.2.6 Event log 9-10
7.0 OPERATION 10
7.1 Starting the engine 10
7.2 Stopping the engine 10
7.3 Stop/Reset mode 10-11
7.4 Manual mode 11
7.4.1 Starting sequence 11
7.4.2 Stopping sequence 11
7.5 Automatic mode 11
7.5.1 Waiting in auto mode 11
7.5.2 Starting sequence 11-12
7.5.3 Stopping sequence 12
7.6 Stop mode 12
7.7 Manual mode 12
8.0 Protections 12
8.1 Alarms 12
8.2 Warning alarms 12-13
8.3 Electrical trip alarms 13-14
8.4 Shutdown alarms 14-15
8.5 High current shutdown 15
8.5.1 Immediate warning 15
8.5.2 IDMT alarm 15-16
8.6 Maintenance alarm 16
9.0 Front panel configuration editor 16
9.1.1 Accessing the front panel editor 16
9.1.2 Entering pin 16
9.1.3 Editing a parameter 16-17
9.1.4 Exiting the front panel configuration editor 17
10.0 Fault finding 6110MKII 17
10.1 Alarms 17
11.0 Fault finding general 18-19
12.0 Spares 19
12.1 Perkins consumable spares 19
12.2 SSDP33-70 Spares 19
12.3 General spares 19-20
13.0 Service and maintenance 20
13.1 Engine service 20
13.2 Light loading 20
13.3 Alternator service 20
14.0 Warranty 20-21
33-36kVA 400V Wiring DSE 6110MKII 22
50-67kVA 400V Wiring DSE 6110MKII 23
Perkins 1100 series DC Wiring DSE 6110MKII 24
SSDP33-70 MK2 Exploded view 25
SSDP33-70 Canopy parts list 26
Issue 4
1 SPECIFICATION
Note
Fuel tank working capacity
P33 = 260 Litres P50/67 = 330 Litres
Hours run are based on these figures.
2 GENERAL SAFETY
2.1 Warning signs
Warnings shown on the machine should be observed at all times. The warning signs should be
checked for legibility and any that have become damaged should be replaced.
3 POTENTIAL HAZARDS
3.1 Auxiliary power
The electricity produced by an engine driven Generator is very similar to mains electricity and should
be treated accordingly.
Do not remove covers and attempt to work on the Generator while the engine is running.
Check the rating and electrical safety of the load before connecting the Generator.
Equipment should never be connected that in total exceeds the specified rating of the Generator.
Installation of the generator as a standby or secondary power source should only be undertaken by a
fully qualified electrician using the appropriate means of isolation from the mains supply. Installation
must comply with all applicable laws and electrical codes.
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3.2 Operating Environment
The Generator should always be operated on ground level.
4 SAFETY CONSIDERATIONS
4.1 General
All Stephill Generators comply with all the current EEC directives including:
2006/42/EC Machinery Directive
2000/14/EC Noise Emission in the Environment by Equipment for use Outdoors
2004/108/EC EMC Directive
2006/95/EC Low Voltage Directive
4.2 Fuel
Fuels and lubricants are a potential source of fire. Be careful not to spill fuel, clean up any spillages.
Inhalation or swallowing of Diesel should be avoided. If in doubt seek medical advice. All other forms
of contact are irritant and therefore should also be avoided. If skin contact is made wash with soap
and water.
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4.6 Earth connection
All Stephill products are fitted with an earth stud on the control panel this must be connected to an
earthing system or spike. Any earth spike required is dependant on the local conditions of use. The
size is determined by reference to current IEE regulations or to a competent electrician.
4.7 Fumes
Make sure that the Generator is at least 2 metres away from any building during operation. Operate
in a well ventilated unconfined area, so that fumes can be properly dispersed. Silencer outlet should
be facing an open area to prevent fumes being recirculated. There is the danger of asphyxiation due
to exhaust gases. Inhalation of poisonous exhaust fumes can lead to serious injury or death. The
generator must not be used in a poorly ventilated or enclosed area.
4.8 Noise
Ear protection may be required depending on the combined noise level of the Generator, auxiliary
load and the operator’s distance from it and the length of exposure. (Noise at Work Regulations
1989)
4.10 Fire
Ensure that suitable fire extinguishers (AFFF or CO 2) are kept within close proximity of the generator.
Do not cover, enclose, or obstruct the airflow to the generator during or shortly after use, due to fire
hazard or damage to the generator from overheating. Allow the generator to cool after use before
storing away. Keep all inflammable objects clear of the Generator.
5 OPERATING INSTRUCTIONS
5.1 Pre-start checks
Before starting the generator please read the engine owners manual. Check Fuel ‘Water & Oil level
before attempting to start. Ensure 3 way valve is in correct position. This engine is equipped with an
oil’ temperature and low water level switch and will shutdown for any of these fault conditions. Inspect
the generator visually for signs of fault or damage. Ensure battery isolator switch is switched on.
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If this is not possible turn the circuit breaker to the off position.
Connect the plugs into the generator.
Switch on the load / Circuit breaker.
This unit is also fitted with individual Circuit Breakers on each socket.
Warning
Always switch load off before disconnecting plugs.
To switch power off at Generator always use circuit breaker.
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5.9 Long term storage
For storage or long periods of inactivity, Stephill Generators recommend the following:
Generators should be stored with oil filled to the correct capacity; Storage periods of 18 months and over may
require special lubricants and treatments. If so please seek further advice from the engine manufacturer.
Before the generator is used after long term storage, all fuels and oils should be replaced.
Generator mounts, pipes and hoses should be checked to ensure that they are un-perished following
extended periods of storage.
The generator should be stored in a clean dry area, ideally having a reasonable constant ambient
temperature, and ideally not below freezing. The battery isolator switch should be switched off.
Control of the module is via push buttons mounted on the front of the module with Stop/Reset Mode ,
Manual Mode , Auto Mode and Start functions. For normal operation, these are the only controls
which need to be operated.
Details of their operation are provided later in this document.
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Control push buttons
Icon Description
Stop / Reset Mode
This button places the module into its Stop/Reset Mode . This clears any alarm conditions
for which the triggering criteria have been removed. If the engine is running and the module is
put into Stop mode, the module automatically instructsthe generator to unload (Close
Generator and Delayed Load Output 1, 2, 3 & 4become inactive (if used)). The fuel supply
de-energises and the engine comes to a standstill. Should any form of remote start signal be
present when in Stop Mode the generator remains at rest
Manual Mode
This button places the module into its Manual Mode . Once in Manual Mode , the
module responds to the Start button to start the generator and run it off load.
Auto Mode
This button places the module into its Auto Mode . This mode allows the module to control
the function of the generator automatically. The module monitors the remote start input and
once a start request is made, the set is automatically started and placed on load
Upon removal of the starting signal, the module removes the load from the generator and
shut the set down observing the stop delay timer and cooling timer as necessary. The module
then waits for the next start event.
Alarm Mute / Lamp Test
This button de-activates the audible alarm output (if configured) and illuminates all of the
LEDs on the module’s facia.
Start
This button is only active in the Stop/Reset Mode and Manual Mode.
Pressing the Start button in Manual Mode starts the generator and runs it on load.
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Menu Navigation
Used for navigating the instrumentation, event log and configuration screens.
For further details, please see section entitled ‘Operation’ elsewhere in this
manual.
The complete order and contents of each information page are given in the following sections.
Once selected, the page remains on the LCD display until the user selects a different page, or after an
extended period of inactivity (LCD Page Timer), the module reverts to the status display.
If no buttons are pressed upon entering an instrumentation page, the instruments displayed are
automatically subject to the setting of the LCD Scroll Timer.
The screenshot below shows the factory settings for the timers, taken from the DSE Configuration
Suite PC Software.
Alternatively, to scroll manually through all instruments on the currently selected page, press either of
the Menu Navigation buttons. The ‘auto scroll’ is disabled.
To re-enable ‘auto scroll’ press and hold either of the Menu Navigation buttons to scroll to
the ‘title’ of the instrumentation page (ie Engine). A short time later (the duration of the LCD Scroll
Timer), the instrumentation display begins to auto scroll.
When scrolling manually, the display automatically returns to the Status page if no buttons are
pressed for the duration of the configurable LCD Page Timer.
If an alarm becomes active while viewing the status page, the display shows the Alarms page to draw
the operator’s attention to the alarm condition.
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6.2.1 STATUS
This is the ‘home’ page, the page that is displayed when no other page has been selected, and the
page that is automatically displayed after a period of inactivity (LCD Page Timer) of the module
control buttons.
This page changes with the action of the controller, when the engine is running, that target speed is
displayed.
6.2.3 ENGINE
These pages contain instrumentation gathered about the engine measured or derived from the
module’s inputs.
• Engine Speed
• Oil Pressure
• Coolant Temperature
• Engine Battery Volts
• Engine Run Time
• Fuel Consumption
• Fuel Used
• Fuel Level
• Flexible Sensors
• Engine Maintenance Alarm 1
• Engine Maintenance Alarm 2
• Engine Maintenance Alarm 3
6.2.4 GENERATOR
These pages contain electrical values of the generator, measured or derived from the module’s
voltage inputs.
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• Generator Current (A)
• Generator Load ph-N (kW)
• Generator Total Load (kW)
• Generator Load ph-N (kVA)
• Generator Total Load (kVA)
• Generator Power Factor Average
• Generator Load ph-N (kVAr)
• Generator Total Load (kVAr)
• Generator Accumulated Load (kWh, kVAh, kVArh)
• Generator Phase Sequence
• Active Configuration
6.2.5 ALARMS
When an alarm is active, the Common Alarm LED, illuminates and a message appears on the module’s
display. If configured, the external audible alarm also sounds.
The external audible alarm is silenced by pressing the Alarm Reset / Lamp Test button.
The LCD display jumps from the ‘Information page’ to display the Alarm Page
The LCD displays multiple alarms such as “Coolant Temperature High”, “Emergency Stop” and “Low
Coolant Warning”. These automatically scroll in the order that they occurred.
In the event of an alarm, the LCD displays the appropriate text. If an additional alarm then occurs,
the module displays the appropriate text.
Example:
The module maintains a log of past alarms and/or selected status changes.
The log size has been increased in the module over past module updates and is always subject to change. At
the time of writing, the modules log is capable of storing the last 50 log entries.
Under default factory settings, the event log is configured to include all possible options; however, this is
configurable by the system designer using the DSE Configuration Suite software.
Factory settings
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When the event log is full, any subsequent event overwrites the oldest entry. Hence, the event log always
contains the most recent events. The module logs the event type, along with the date and time (or engine
running hours if configured to do so).
To view the event log, press and hold either of the Menu Navigation buttons to scroll to the Event
Log page.
Press the Scroll Down button to view the next most recent event.
Continuing to press the Scroll Down button cycles through the past events after which, the
display shows the most recent alarm and the cycle begins again.
To exit the event log and return to viewing the instruments, press and hold either of the
Menu Navigation buttons to select the next instrumentation page.
7 OPERATION
7.1 STARTING THE ENGINE
Manual Start
Press the Manual Mode button.
Press the Start button.
If the engine does not stop when requested, the Fail To Stop alarm is activated (subject to the setting
of the Fail to Stop timer). To detect the engine at rest the following must occur :
When the engine has stopped, it is possible to send configuration files to the module from DSE
Configuration Suite PC software and to enter the Front Panel Editor to change parameters.
Any latched alarms that have been cleared are reset when Stop/Reset Mode is entered.
The engine is not started when in Stop/Reset Mode . If remote start signals are given, the input is
ignored until Auto Mode is entered.
When left in Stop/Reset Mode with no presses of the fascia buttons and configured for Power
Save Mode, the module enters Power Save Mode. To ‘wake’ the module, press any fascia control
buttons.
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7.4 MANUAL MODE
Manual Mode is activated by pressing the Manual Mode button.
In Manual Mode , the set does not start automatically
To begin the starting sequence, press the Start button.
If the engine fails to fire during this cranking attempt then the starter motor is disengaged for the Crank Rest
Timer duration after which the next start attempt is made. Should this sequence continue beyond the set
Number Of Attempts, the start sequence is terminated and the display shows Fail to Start.
The starter motor is disengaged when the engine fires. Speed detection is factory configured to be derived
from the AC alternator output frequency.
Additionally, rising oil pressure can be used to disconnect the starter motor (but cannot detect underspeed or
overspeed).
After the starter motor has disengaged, the Safety On Delay timer activates, allowing Oil Pressure,
High Engine Temperature, Under-speed, Charge Fail and any delayed Auxiliary fault inputs to stabilise
without triggering the fault.
If the engine fails to fire during this cranking attempt then the starter motor is disengaged for the Crank Rest
duration after which the next start attempt is made. Should this sequence continue beyond the Set Number Of
Attempts, the start sequence is terminated and the display shows Fail to Start.
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The starter motor is disengaged when the engine fires. Speed detection is factory configured to be
derived from the AC alternator output frequency, but can additionally be measured from a Magnetic
Pickup mounted on the flywheel or from the CAN link to the engine ECU depending on module
Additionally, rising oil pressure can be used to disconnect the starter motor (but cannot detect
underspeed or overspeed).
The Return Delay timer operates to ensure that the starting request has been permanently removed and isn’t
just a short term removal. Should another start request be made during the cooling down period, the set
returns on load.
If there are no starting requests at the end of the Return Delay timer, the load is removed from the generator
to the mains supply and the cooling timer is initiated.
The Cooling Down timer allows the set to run off load and cool sufficiently before being stopped. This is
particularly important where turbo chargers are fitted to the engine.
After the Cooling Down timer has expired, the set is stopped.
8 PROTECTIONS
8.1 ALARMS
When an alarm is active, the Common Alarm LED, illuminates and a message appears on the module’s
display. If configured, the external audible alarm also sounds.
The external audible alarm is silenced by pressing the Alarm Reset / Lamp Test button.
The LCD display jumps from the ‘Information page’ to display the Alarm Page
The LCD displays multiple alarms such as “Coolant Temperature High”, “Emergency Stop” and “Low Coolant
Warning”. These automatically scroll in the order that they occurred.
In the event of an alarm, the LCD displays the appropriate text. If an additional alarm then occurs, the module
displays the appropriate text.
Example:
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Example:
In the event of an alarm the LCD jumps to the alarms page, and scroll through all active alarms.
By default, warning alarms are self-resetting when the fault condition is removed.
Fault Description
Analogue Input A to D The module detects that an input configured to create a fault condition has
become active and the appropriate LCD message is displayed.
Battery Over Voltage The DC supply has risen above the high volts pre-set pre-alarm setting.
Battery Under Voltage The DC supply has fallen below or risen above the low volts preset pre-
alarm setting.
Charge Alternator Failure The auxiliary charge alternator voltage is low as measured from the W/L
terminal.
Coolant Temperature Sensor The module detects that the circuit to the coolant temperature sensor has
Fault been broken.
Delayed Over Current The measured current has risen above the configured trip level for a
configured duration.
Digital Inputs A to F The module detects that a digital input which has been user configured to
create a fault condition has become active and the appropriate LCD
message is displayed.
Expansion Unit Failure The module detects the DSE Net link to the expansion module has failed or
communications to the expansion module has been lost.
Fail To Stop
The module has detected a condition that indicates that the engine is
running when it has been instructed to stop.
Low Fuel Level The level detected by the fuel level sensor is below the low fuel level pre-set
pre-alarm setting.
Maintenance Alarm 1 The module detects that the Maintenance Alarm 1 is due creating a fault
condition, the appropriate LCD message is displayed.
Maintenance Alarm 2 The module detects that the Maintenance Alarm 2 is due creating a fault
condition, the appropriate LCD message is displayed.
Maintenance Alarm 3 The module detects that the Maintenance Alarm 3 is due creating a fault
condition, the appropriate LCD message is displayed.
Oil Pressure Sensor Fault The module detects that the circuit to the oil pressure sensor has been
broken.
Electrical trips are latching and stop the Generator but in a controlled manner. On initiation of the electrical trip
condition the module de-energises all the Delayed Load Output and the Close Gen Output outputs to remove
the load from the generator. Once this has occurred the module starts the Cooling timer and allows the
engine to cool off-load before shutting down the engine. The alarm must be accepted and cleared, and the
fault removed to reset the module.
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Example:
Electrical trips are latching alarms and to remove the fault, press the Stop/Reset Mode button on the
module.
Fault Description
Analogue Input A to D The module detects that an input configured to create a fault
condition has become active and the appropriate LCD message is
displayed.
Digital Inputs A to F The module detects that a digital input which has been user configured to
create a fault condition has become active and the appropriate LCD message is
displayed.
Expansion Unit Failure The module detects the DSE Net link to the expansion module has failed or
communications to the expansion module has been lost.
Low Fuel Level The level detected by the fuel level sensor is below the low fuel
level pre-set pre-alarm setting.
Shutdown alarms are latching and immediately stop the Generator. On initiation of the shutdown condition the
module de-energises all the Delayed Load Output and the Close Gen Output outputs to remove the load from
the generator. Once this has occurred, the module shuts the generator set down immediately to prevent
further damage. The alarm must be accepted and cleared, and the fault removed to reset the module.
Example:
Shutdowns are latching alarms and to remove the fault, press the Stop/Reset Mode button on the module.
Fault Description
Analogue Input A to D The module detects that an input configured to create a fault condition has
become active and the appropriate LCD message is displayed.
Charge Alternator Failure The auxiliary charge alternator voltage is low as measured from the W/L
terminal.
Coolant Temperature The module detects that the circuit to the coolant temperature sensor has been
Sensor Fault broken.
Emergency Stop The emergency stop button is pressed. This failsafe (normally closed to
emergency stop) input and immediately stops the set when the signal is
removed.
Delayed Over Current The measured current has risen above the configured trip level for a configured
duration.
Digital Inputs A to F The module detects that a digital input which has been user configured to
create a fault condition has become active and the appropriate LCD message is
displayed.
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Expansion Unit Failure The module detects the DSE Net link to the expansion module has failed or
communications to the expansion module has been lost
Generator kW Overload The measured kW has risen above the configured trip level for a configured
duration.
Generator Over Frequency The generator output frequency has risen above the trip alarm setting.
Generator Over Voltage The generator output voltage has risen above the trip alarm setting.
Generator Under The generator output frequency has fallen below the trip alarm setting after the
Frequency Safety On timer has expired.
Generator Under Voltage The generator output voltage has fallen below the pre-set alarm setting after the
Safety On timer has expired.
High Coolant Temperature The module detects that the engine coolant temperature has exceeded the high
engine temperature trip alarm setting level after the Safety On timer has
expired.
Low Fuel Level The level detected by the fuel level sensor is below the low fuel level trip alarm
setting.
Low Oil Pressure The module detects that the engine oil pressure has fallen below the low oil
pressure trip alarm setting level after the Safety On timer has expired.
Oil Pressure Sensor Fault. The module detects that the circuit to the oil pressure sensor has been broken.
Over Speed The engine speed has risen above the over speed trip alarm setting.
Under Speed The engine speed has fallen below the under speed trip alarm setting.
High current electrical trip is a latching alarm and stops the Generator.
Remove the fault then press the Stop/Reset Mode button to reset the module.
The higher the overload, the faster the trip. The speed of the trip is dependent upon the fixed formula:
T = t / ((IA / IT) – 1) 2
Where: T is the tripping time in seconds
IA is the actual current of the most highly loaded line (L1 or L2 or L3)
IT is the delayed over-current trip point
t is the time multiplier setting and also represents the tripping time in seconds at twice full load (when IA / IT =
2).
Factory settings for the IDMT Alarm when used on a brushless alternator are as follows (screen capture from
the DSE Configuration Suite PC software :
t (time multiplier)
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These settings provide for normal running of the generator up to 100% full load. If full load is surpassed, the
Immediate Warning alarm is triggered, the set continues to run.
The effect of an overload on the generator is that the alternator windings begin to overheat; the aim of the
IDMT alarm is to prevent the windings being overload (heated) too much. The amount of time that the set can
be safely overloaded is governed by how high the overload condition is.
With typical settings as above, this allows for overload of the set to the limits of the Typical Brushless
Alternator whereby 110% overload is permitted for 1 hour.
When activated, the maintenance alarm is a Warning and set continues to run.
Resetting the maintenance alarm is actioned by the site service engineer after performing the required
maintenance. The method of reset is by breaking the connection between wires 43 & 1 which are located at
the side of the MCCB. Panel must be powered up for re-set to operate.
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Press and hold either of the Menu Navigation buttons to cycle to the section which is
required to be edited.
Press the Menu Navigation buttons to cycle to the parameter within the section chosen to
be edited.
Press the Tick button to edit the parameter. The parameter begins to flash to indicate that the
parameter is being edited.
Press the Previous ─ & Next + buttons to adjust the parameter to the required value.
Press the Tick button to stop editing the parameter. The parameter ceases flashing to indicate
that it the parameter is no longer being edited.
Press and hold the Stop/Reset Mode button to exit the editor without saving changes.
Press and hold the Tick button to exit the editor and save the changes.
10.1 ALARMS
Low oil Pressure fault Check engine oil pressure. Check oil pressure switch/sensor and wiring.
operates after engine has fired Check switch is Normally Closed at rest and opens when running.
High engine temperature fault Check engine temperature. Check switch/sensor and wiring.
operates after engine has fired. Check switch is Normally Open and closes to fault.
Shutdown fault operates Check relevant switch and wiring of fault indicated on LCD display.
Electrical Trip fault operates Check relevant switch and wiring of fault indicated on LCD display.
Warning fault operates Check relevant switch and wiring of fault indicated on LCD display.
Incorrect reading on Engine Check engine is operating correctly. Check sensor and wiring paying
gauges particular attention to the wiring to terminal 10 (refer to appendix).
Fail to stop alarm when engine Check that Oil sender wiring is correct and correctly earthed.
is at rest
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11 Fault finding general
Fault Action
High engine Check Water/Antifreeze level in the radiator.
temperature Check for loose wires on the temperature switch & DC loom connector block.
Check the continuity of the earth wire. (Refer to wiring diagram)
Check radiator surface (both sides) and fins are not obstructed.
Check operation of the Temperature switch.
Check that the generator air inlets and outlets are not obstructed.
Check the fan belt is not damaged, broken or loose. (Refer to handbook)
Note you may experience low charge if fan belt is loose.
Low oil pressure Check Oil level and fill to correct level if necessary
Check for loose wires on the Oil switch & DC loom connector block.
Check the continuity of the earth wire. (Refer to wiring diagram)
Check operation of Oil switch.
HZ & Voltage Check reset button not tripped and reset if required.
shutdown Check AC Input at module. 115V or 230V (Dependant on type of generator)
Check engine speed is set to 52.5Hz at no load. Adjust if required (Speed should
be set when engine is cold)
Check AC supply from alternator. (If no output refer to alternator handbook)
Check fuse on AVR.
Check engine has been regularly serviced.
No power to Check fuse.
control Check 12V DC supply to module. If supply present but not operational try new unit.
module Check battery voltage.
Check battery isolator switch is on.
Check for loose wires on battery isolator.
Check for loose wires on the DC connector plug and socket.
Check continuity on +VE and -VE wires to battery.
Battery not Note you may experience low charge if fan belt is loose.
charging Check for loose wires on the DC connector plug / socket & charge alternator.
Check continuity of all wires from charge alternator. (Refer to wiring diagram)
Check voltage at battery while generator is running, voltage should be 13.4 - 14.4V.
Check battery voltage is above 12.5V.
Engine not Check Oil level and fill to correct level if necessary.
starting Check fuel level.
Check 3 way valves are in correct position. (If fitted)
Check operation of fuel lift pump.
Check fuel is reaching the injectors. When running correctly fuel should be running freely
from the injector return pipe. If no fuel running from return check the fuel filters & check
condition of fuel.
Check no air in system. Keep fuel pump running using prime button for 60 secs.
Glow plugs not Check Emergency stop.
operating Check the fuses.
Check battery voltage is above 12.5V.
Check for loose wires on the Glow plug, relays, fuses, module terminals, plug and socket.
Glow plugs not Check -VE supply.
operating Check +VE on Glow plug & trace back to battery via relay.
Check +VE on Glow plug & trace back to module via relay, plug & socket.
Starter Motor not Check Emergency stop.
operating Check the fuses.
Check battery voltage is above 12.5V.
Starter Motor not Check for loose wires on the solenoid, relays, fuses, module terminals, plug and socket.
operating Check +VE supply from battery to starter motor via isolator switch.
Check -VE supply.
Check start terminal on Starter motor & trace back to module via relay, plug & socket.
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Fuel solenoid not Does the Fuel solenoid energises when the starter motor turns over.
operating Check Emergency stop.
Check the fuses.
Check battery voltage is above 12.5V.
Check for loose wires on the solenoid, relays, fuses, module terminals, plug and socket.
Check -VE supply.
Check +VE on Fuel solenoid & trace back to battery via relay.
Check +VE on Fuel solenoid & trace back to module via relay, plug & socket.
12 SPARES
12.1 Perkins consumable spares
Owing to the amount of times Perkins amends the parts they fit to each engine we will require the full engine
build list and serial number. The build list number is generally two letters followed by five numbers with the
serial number usually beginning with a J, N or a U followed by six numbers and a final letter. E.g.:
AA12345U123456X.
Usually the part numbers are on the filters or in the case of air filters on the air cleaner cover.
We have implemented writing the part numbers to the test sheet should the numbers become illegible in
which case quote the Stephill Generators serial number.
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Part Number Description Qty
056-0005 Relay base 30Amp 1
036-0069 Fuse holder 1
036-0101 30Amp fuse 1
036-0058 50 Amp fuse 1
045-0031 150/5 Current transformer 3
036-0023 50Amp 4 Pole MCB 1
036-0037 63Amp 4 Pole RCD 30mA 1
036-0016 32Amp 3 Pole MCB 1
036-0014 32Amp 1 Pole MCB 3
038-0103 M8 Terminal stud 5
036-1050 Barrier terminal 2
036-1051 Barrier terminal end plate 1
027-0007 M10 Rubber foot (Door stop) 2
054-0010 Battery 660 CCA – Cold cranking amps to SAEJ537 1
038-0105 Battery terminal cover Red 1
038-0106 Battery terminal cover Black 1
045-0020 Battery isolator switch 1
044-0014 400V 32Amp Socket 1
044-0004 230V 32Amp Socket 3
039-0001 DC Engine wiring loom 1
039-0002 DC Panel loom 1
IMPORTANT WARNING:
After any service on the generator, ensure that all piping and electrical cables are correctly routed and
secured away from hot parts. Failure to observe this warning may result in damage to the piping and cables
which could result in a fire.
Do not service or work on generator whilst the engine is running. Ensure battery isolator switch is in the
off position when working on generator, this will prevent generator from starting.
Issue 4 20
14 WARRANTY
STEPHILL GENERATORS LTD will accept no responsibility whatsoever for equipment that has failed due
to;
- Operation with incorrect fuel, lubricating oil or coolant.
- Improper repair or use of parts not supplied by STEPHILL GENERATORS LTD.
- Lack of, or incorrect maintenance.
- Fair wear and tear, misuse, negligence, accidental damage, improper
storage, incorrect starting / warm-up / run-in or shutdown.
No warranty claim will be considered by STEPHILL GENERATORS LTD unless any defective parts are
available for inspection by us, or our nominees, to determine the reason or cause of failure, and STEPHILL
GENERATORS LTD is given the option of repair or replacement.
STEPHILL GENERATORS LTD are not responsible for incidental or consequential damages, downtime, or
other costs due to warrantable failure, and unauthorised alterations made to any product supplied by
STEPHILL GENERATORS LTD.
Issue 4 21
50A MCB 50A RCD 32A MCB
1 6mm Brown 6mm Brown 4mm Brown
37 33
5 6mm Black 6mm Black 4mm Black
37 34 4mm Grey
9 6mm Grey 6mm Grey
3 32A MCB
LINK L3 L2
6
7 32A MCB
N L1
E
LINK
1.5mm Brown
1.5mm Black
10
1.5mm Grey
11
32A MCB
LINK
4
6mm Blue 28 16A MCB 4mm Blue
8
12
32A 230V Socket
4mm Brown
6mm Green/Yellow
L N
EARTH
Hard wire terminals
E
6mm Brown
6mm Black
4mm Blue
6mm Grey
32A 230V Socket
DSE Deep Sea Electronics 6110 MK2
1.5mm Black L N
COM 37 6mm Green/Yellow
COM 36
E
1.5mm Black
CT3 35
1.5mm Black
CT2 34
1.5mm Black
CT1 33
4mm Blue
1.5mm Blue
1.5mm Grey
L N
37 33
5 16mm Black 10mm Black 10mm Black
1.5mm Brown
32A MCB
1.5mm Black
ALTERNATOR
1.5mm Grey
1.5mm Blue
4mm Brown
16mm Blue
12 81 84 SHUNT TRIP 400V 63A SOCKET
1.5mm Brown
4mm Black
L3 L2
EARTH
4mm Grey
16mm Green/Yellow
28 1.5mm Blue N L1
4mm Blue E
1.5mm Black
1.5mm Black
2
7 L3 L2
10 N L1
E
11
4mm Blue
4mm Brown
1.5mm Brown
E
1.5mm Black
COM 37 ELR-3C
4mm Blue 32A RCBO
DSE 6110 MK2
COM 36
4mm Black
1.5mm Black
CT3 35
1 2 3 4 5 6 7 8 9 4mm Blue
1.5mm Black
CT2 34
82 28
1.5mm Black
CT1 33 4mm Black
82
1.5mm Blue 32A RCBO
32A 230V Socket
1.5mm Grey
1.5mm Blue 28
N 28
1.5mm Grey 27 2A 1.5mm Grey L N
W 27
1.5mm Black 26 2A 1.5mm Black
V 26 E
1.5mm Brown 25 25 2A 1.5mm Brown
U 25 Hard wire terminals
RCD BYPASS
82 OFF 1.5mm Brown 16mm Brown
1.5mm Brown 25
80 ON
1.5mm Grey
16mm Grey
16A 230V Socket
16mm Blue
L N
80 16mm Green/Yellow
NOTE BYPASS SWITCH ON E
50kVA = 80A MCB
67kVA = 100A MCCB 28
1.5mm Blue
2.5mm
2.5mm
50A
54 52 6/10mm
(4)
6 6
GLOW PLUG
PRE-HEAT
(15)
9 9 9 1
USB R3
(D) 15
PROGRAMMING
PORT FUEL SENDER (C) 14 54 55 6/10mm 55
DSE Deep Sea Electronics 6110 MK2
(7)
OPEN TO RESET
40 40 40 1 1
43
COOLANT SWITCH
1
(9)
41 41 51 C A D 41
B 1 1
1 (10)
12 12 12
38 REMOTE START -VE
OIL SENDER
(11)
13 13 13
2 BATTERY +VE
1 BATTERY -VE
TEMPERATURE SENDER
14
1
Black
Black
Legend
CLOSE TO START
1 = Cable numbers
(1) = Terminal numbers
FOZMULA FR370
R1 / R2 = 30A Relay FUEL LEVEL SENDER
1
R3 = 100A Relay
BLACK
GREEN
RED
40
41
42
19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 37 38