Mastervolt WHISPER 20 ULTRA User Manual

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Page 1

MASTERVOLT

Snijdersbergweg 93

1105 AN Amsterdam

The Netherlands

Tel.: +31-20-3422100

Fax: +31-20-6971006

www.mastervolt.com

USERS MANUAL

U.S.A. EDITION

V1. April 2004

WHISPER 20 ULTRA

-1800 RPM-

Marine diesel generating set 120/240V-60 Hz

Digital Diesel Control

Art.nr. 50200414

Page 2

2 May 2003 / WHISPER 20 ULTRA / USA

CONTENTS

This manual applies to the Mastervolt Whisper 20 ULTRA marine

generating set controlled by Digital Diesel Control. First launched in April

2004. For earlier models refer to other manuals available on our website:

www.mastervolt.com

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 Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

2 INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

2.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

2.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

2.1.2 Electrical safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

2.1.3 Earth insulation failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

2.1.4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

2.1.5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

2.1.6 Fire and explosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

2.1.7 Chemicals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

2.2 Transport lifting and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

2.3 The Whisper 20 ULTRA generating set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

2.3.1 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

2.3.2 Remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

2.3.3 Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

2.3.4 Accessories included in the delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

2.4 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

2.4.1 Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

2.4.2 Generator control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

2.4.3 Remote control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

2.5 Technical information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

2.5.1 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

2.5.2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

2.5.3 DC electrical control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

2.5.4 Battery charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

2.5.5 Alarms and shut down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

2.5.6 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

2.5.7 Remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

2.5.8 Hour counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

2.5.9 Load indicattor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

2.5.10 Fuel specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

2.5.11 Oil specification, oil viscosity, oil capacity,, oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Page 3

USA / WHISPER 20 ULTRA / May 2003 3

CONTENTS

2.5.12 Cooling liquid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

2.5.13 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

2.5.14 Wiring, codes and colours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

2.5.15 Lay out control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

2.5.16 Electrical diagram 120/240V 60Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

2.5.17 Diagram electronic governor (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

3.2 Operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

3.2.1 Summarised operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

3.2.2 Extended operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

4 MAINTENANCE AND CARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

4.1 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

4.2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

4.2.1 General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

4.2.2 Bleeding fuel lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

4.2.3 Valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

4.2.4 Replacing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

4.2.5 Replacing the oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

4.2.6 Readjusting V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

4.3 Regular maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

4.3.1 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

4.3.2 Putting out of service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

5 TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

5.1 Alternator malfunctions / AC trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

5.1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

5.1.2 Trouble shooting check list alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

5.2 Engine malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

5.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

5.2.2 Trouble shooting check list engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

5.2.3 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

5.2.4 Service address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

5.3 Special procedures alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

5.3.1 Residual voltage check / excitation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

5.3.2 Testing rotary diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

5.3.3 Windings resistance values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

5.3.4 Meggering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

5.4 Special procedures engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

5.4.1 Readjusting RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

5.4.2 Valve clearance / retightening cylinder head bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

5.4.3 Measuring exhaust by backpressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

5.4.4 Disassembly instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

6SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Maintenance log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Page 4

4 May 2003 / WHISPER 20 ULTRA / USA

INTRODUCTION

1 INTRODUCTION

The Whisper 20 ULTRA Marine Diesel Generating set is

manufactured and marketed by Mastervolt.

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 well understanding of ratings, features, design,

maintenance and operation procedures.

The information, specifications, illustrations and state-

ments contained within this publication are given with our

best intentions and are believed to be correct at the time

of going to press.

Our policy is one of continued development and we re-

serve the right to amend any technical information with-

out 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 consequen-

ces thereof.

WARNING:

A warning symbol draws attention to spe-

cial warnings, instructions or procedures

which, if not strictly observed, may result in

damage or destruction of equipment, seve-

re personal injury or loss of life.

DANGER:

This danger symbol refers to electric dan-

ger and draws attention to special war-

nings, instructions or procedures which, if

not strictly observed, may result in electri-

cal shock which will result in severe per-

sonal injury or loss of life.

1.2 SERVICE AND MAINTENANCE

Regular service and maintenance should be executed

according the directions in this manual. For service and

maintenance one can appeal to the manufacturer or the

dealers.

1.3 GUARANTEE

Mastervolt 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 genera-

ting 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 in

Amsterdam number 33279951 and are available on request.

The guarantee period is two years, limited to 1000 running

hours. For U.S.A. deliveries there are additional conditions.

These are available at Mastervolt U.S.A. Some aspects of

the warranty scheme are given here in more detail:

Guarantee period 1000 running hours or 24 months

whichever occurs first. Warrantee does not cover failures

that are caused by misuse, neglect or a faulty installation.

Example 1. Faulty installation:

Seawater entering the engine is the most common cause of

damage to combustion engines in boats. (Both to propulsion

and generator engines.) The entry of water must be avoided

under all conditions. Be aware that the conditions in blue

water sailing can be extreme. 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.

DAMAGE CAUSED BY THE INGRESS OF

WATER IS NEVER COVERED BY

WARRANTEE.

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 warrantee.

Example 3: Neglect

Sometimes the seal of the raw water pump starts leaking.

Mostly this begins with a little drip and slowly gets worse.

Regular visual inspection of the generator is necessary to

prevent damage to occur from a leaking water pump.

When one find serious damage after weeks of neglect

warrantee claims will not be honoured.

Example 4: Neglect

Whisper generators have an option for an auto start/stop

mode or interval mode.

Page 5

USA / WHISPER 20 ULTRA / May 2003 5

INTRODUCTION

Mastervolt cannot be held responsible for damage

caused by the unattended running generator.

Warranty 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

vessel executed by an authorised 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 boat or for reinstallation. There is no cover for labour

needed to get access to the generator, for example to

remove equipment or bulkheads etc.

Goods to be delivered under warrantee 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 warranty a credit will not be issued. For example if a

Printed Circuit Board is returned with clear damage

caused by seawater, warranty will be refused.

Freight costs to deliver spares by normal mail or carriers

is covered under warranty. Special services like express

mail, overnight delivery etc. are not covered. Taxes and

duties are not covered. For shipments to remote off

shore areas any additional costs incurred over normal

carriage will be invoiced to the customer.

The cost for returning faulty goods is not covered under

warranty.

If any problem arise which could be subject of guarantee,

procedures should be followed as described in the gua-

rantee certificate, unauthorised repairs could lead to furt-

her damage and violate the guarantee conditions.

Should work take place, which is not in ac-

cordance 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 specifica-

tions. In all these cases the guarantee may

become invalid. Use original parts only

1.4 LIABILITY

Mastervolt 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. Mastervolt does not accept liabi-

lity for damage due to use of the generator, possible errors

in the manuals and the results thereof.

Automatic start/stop

Mastervolt 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 cor-

rect specifications.

1.5.2 Nameplate

All required identification data are on the nameplate.

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

nameplate are also some basic features of the set:

45,28"x 26,77"x 29,57" 1150 x 680 x 750 mm

166 A / 88 A

20 KVA cos phi = 1

50908055

Whisper 20 ULTRA

926 lbs 420 kg

120/240 V

60 Hz

DUAL VOLTAGE

PHASE

DIMENSIONS WxDxH

WEIGHT

ARTICLE NO

MODEL

SERIAL NUMBER

MAX. POWER

VOLTAGE

FREQUENCY

CURRENT

/EPA

Fig. 1: Nameplate.

Page 6

6 May 2003 / WHISPER 20 ULTRA / USA

2 INFORMATION

2.1 SAFETY

2.1.1 General

When correctly installed and used in normal circumstan-

ces 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 has to be taken into account.

Circumstances could make it also neces-

sary to take additional measures. Be awa-

re of wet conditions and hazardous envi-

ronment caused by explosive gasses etc.

2.1.2 Electrical safety

The voltage of 120/240 Volt generated by

this generating set is dangerous and if in-

structions and procedures are not strictly

observed may result in electrical shock

which will result in severe personal injury

or loss of life.

• 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 chan-

ges in your electrical system to be carried out by

qualified electricians.

• Connection and protection must be done in accor-

dance 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.

INFORMATION

2 POWER

The nameplate gives the nominal maximum load in

kVA = kW calculated with the indicated 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

in kW as shown on the nameplate. Power is rated at

an ambient temperature of 104°F (40°C) and a sea-

water temperature of 77°F (25°C). For higher

temperatures the generating set has to be derated.

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

1800 rpm.

5 CURRENT shows the maximum current that is ac-

ceptable at the specified frequency, voltage and po-

wer factor. When a three phase alternator is applied,

the current is divided over three phases.

6 WEIGHT shows the net dry weight (approximately) in

kg. This is without fuel, oil, cooling liquid, packing and

external installation equipment.

7 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, machinery, regarding electric safety

and electric magnetic compatibility (EMC).

Safety also relies on the installation, application and cir-

cumstances. See also the remarks in this manual under

SAFETY

Before changing a factory setting you are advised to con-

sult the manufacturer. When the generating set you have

to identify is not new you have to take into account the

possibility that former users did change the settings.

Check the settings (voltage, frequency, rpm) when any

doubt.

Page 7

USA / WHISPER 20 ULTRA / May 2003 7

INFORMATION

2.1.3 Earth insulation failures

According to local regulations and depending on the ap-

plication it is necessary to take measures for protection

against earth insulation failures. In the U.S.A. version

neutral and ground are connected on the alternator. This

requires an insulation protection device as commonly

used in the U.S.A. This installation is beyond the

influence of Mastervolt and Mastervolt cannot held

responsible for any consequence as a result of the

installation.

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 Masterswitch.

2.1.4 Installation

Whisper generating sets are not self contained

and have to be properly installed in enclosed

areas such as a machine room. Installation

includes measures to be taken to outlet exhaust fumes

which contains carbon monoxide and are extremely

dangerous. Carbon monoxide (CO) is an invisible

odorless 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.

2.1.5 Operation

External moving parts like fans and V-belts are covered

by the canopy and therefore the Whisper 20 ULTRA is

very safe, when the canopy is closed

Never the less take note of the signs on

the generating set which shows symbols in

a triangle indicating danger.

• When service has to be executed while the

engine is running, be aware of moving parts like

V-belts.

• The generating set should be operated by authori-

sed personnel only.

• Be aware of hot parts and specially parts of the

exhaust 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 cor-

rected.

• 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 executing

maintenance.

• Do not change the settings without consulting the

manufacturer. Keep record of changing of the set-

tings 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. Take measures for proper ventilation.

Do not smoke or allow sparks, flames, or other

sources of ignition around batteries.

• Keep a fire extinguisher on hand.

• 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 conta-

minated 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.

Page 8

8 April 2004 / WHISPER 20 ULTRA / USA

INFORMATION

• Engines may be fitted with seals or O-rings

manufactured from "viton" or similar material.

When exposed to abnormal high temperatures in

excess of 750°F (400°C) an extremely corrosive

acid is produced which cannot be removed from

the 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 for personal injuries, do not stand un-

der the generating set.

• Use soft slings to avoid damage.

• On the engine are two lifting eyes, only to be

used to take the generator out of the capsule. Do

not use to lift the set including the capsule and

certainly not including the steel foundation plate !

• 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 mi-

nimise 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 recharge

every 12 weeks.

2.3 THE WHISPER 20 ULTRA

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 gui-

ded through the capsule’s sides. The set is not self con-

tained and is only operable after proper installation using

additional accessories and installation materials.

Installation accessories are listed in the installation ma-

nual and are available through the supplier of the genera-

ting 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 Wisper 3,5.

2.3.3 Documentation

Included in the delivery is this users manual (number:

50200414) an installation manual (number: 50200404)

and a users manual for DCC (number: 50200261).

Not included in the standard delivery but available as an

option are:

• Parts manual; number: 50200184

• Workshop manual; number: 50200173

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.

2.3.4 Accessories included in the standard delivery

• Expansion tank, hose and fittings

•Special hoseconnector for measuring exhaust back

pressure (Refer to paragraph 5.4.3)

Page 9

USA / WHISPER 20 ULTRA / April 2004 9

INFORMATION

Fig. 2: Overview Whisper 20 ULTRA.

2.4 COMPONENTS

2.4.1 Main components to identify

1 Air inlet;

2Starter motor;

3 Battery connection ( negative);

4 Battery connection ( positive);

5 AC 120/240V wiring;

6 AC 120/240V output connection box;

7 Fuel filter;

8 Fuel pipe inlet;

9 Fuel pipe return;

10 Bypass hose air vent;

11 Cooling water in;

12 Exhaust manifold (water cooled);

13 Thermo-switch exhaust;

14 Injector 4x;

15 Glow 4x;

16 Valve cover;

17 Circulation pump;

18 Filling cap oil 2x;

19 Solenoid;

20 Mechanical fuel lift pump;

21 Raw water pump;

22 Cooling liquid temperature switch;

23 Fuel pressure pump

24 Oil pressure switch;

25 Oil sump pump;

26 Exhaust connection;

27 Fuel vent screw;

28 Oil level indicator;

29 Control panel;

30 Capacitors / voltage regulator; (optional)

31 Fuse 1;

32 Fuse 2;

33 Remote control cable;

34 Cooling water injection;

35 RPM adjustment screw;

36 Thermostat housing;

37 Alternator;

38 Filling cap coolant;

39 Heat exchanger;

40 Drain plug coolant;

41 Fail safe;

42 Oil filter;

43 V-belt;

44 Rubbervibricationmounting 4x;

45 Boiler connection;

46 PTO hydropump;

47 Digital Diesel Control unit.

716 191418303231

20 2 5 1

4442 35

27 29

413339254028

183638 45 15 21

13 10 34 12 24 38 11

Page 10

10 May 2003 / WHISPER 20 ULTRA / USA

INFORMATION

2.4.2 Generator control panel

1 Fuse 10A;

2 Fuse 3A;

3 Start/stop button.

2.4.3 Remote control panel

1 Start button;

2 Stop button;

3 Select button;

4 Set button;

5 Failure lamp;

6 Generator load indicator.

7 Display

2.5 TECHNICAL INFORMATION

2.5.1 AC alternator

The single phase synchronous alternator is directly

coupled, one bearing, brushless, rotating field design,

four pole (1800 RPM) and self regulating.

Residual magnetism causes a small voltage over the sta-

tor windings and allows a current to flow in the windings,

which is magnified because of the feed back effect be-

tween rotor and stator. The field windings in the rotor are

short-circuited over a diode to rectify the current. A capa-

citor over an additional winding in the stator which is in

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.

Further technical data on the design of the alternator can

be found in drawings and diagrams in this manual.

2.5.2 Engine

The Whisper generating set is based on the Mitsubishi

S4Q2 4 cylinder diesel engine. The engine is indirectly

injected. The engine is water cooled and the cooling

liquid is cooled by a heat exchanger and raw water. The

heat exchanger and all other parts which are in direct

contact with the raw (sea) water are made of seawater

resistant material like naval brass and gunmetal.

The engine has been specially adapted for the Mastervolt

application and is very different from the standard engine

as 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 is available as optional.

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 on top of the

alternator.

External Fuel Pump Protection-fuse 10 A

Digital Diesel Control Protection-fuse 3 A Remove fuse during maintenance

Whisper Generator Control

Press for start/stop

10 A

3 A

123

Fig. 5: Digital Diesel remote control panel.

Fig.. 3: Control panel.

hold

gnd

tem

str.

exh

oil

reg

alt.

fuel

heat start fuel fail

pull

ct-2

ct-1

ct-2

AC-1

AC-2

Fig.. 4: Digital Diesel Control unit

4 3

Page 11

USA / WHISPER 20 ULTRA / May 2003 11

INFORMATION

2.5.4 Battery charger

On the engine is an alternator generating 50 Amp 12V.

This current is rectified to charge the battery. The

voltage is regulated at 14.2V.

2.5.5 Alarms and shut down

In case of malfunctioning this will be indicated by the fai-

lure light and detail will be shown on the display the

engine will be shut down. There are three functions

guarded: oil pressure, oil temperature and exhaust

temperature.

Exhaust temperature too high indicates the cooling water

to be blocked.

All alarm switches are closed when no malfunction

occurs. A contact is cut in case 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 automaticly. Pushing the STOP

button will stop the engine and the electrical system will

be deactivated. Stopping the engine is executed by the

fuel valve solenoid that will shut off.

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 twisted

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 and

helps to schedule maintenance.

2.5.9 Load indicator

On the remote control the load will be indicated on the

display and by the LEDbar. The load is measured by

current transformers on the alternator.

2.5.10 Fuel specification

The engine must only be used with diesel fuel oil which

conforms the standards for use in modern diesel en-

gines. Fuel free from water and contaminants is of the ut-

most importance.

2.5.11 Oil information

1Specification:

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 CC or CD.

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 this

recommendations.

Using the wrong specification will cause

high oil consumption.

2 Oil viscosity:

We recommend a multigrade oil 10W40.

3 Oil capacity:

Excluding the oil filter the content of the crankcase is

7,4 US qts. (7 l.) Including the oil filter it is 8,5 US qts

(8 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 ± 196 to 392 Kpa (2-4

kgf/cm2/ 28 to 57 psi)(2-4 bar).

Page 12

12 May 2003 / WHISPER 20 ULTRA / USA

INFORMATION

2.5.13 Technical data

GENERAL

Model WHISPER 20 ULTRA RPM 1800 rpm Alternator water cooled, synchronous Engine Mitsubishi diesel, model S4Q2 (Japan) Number of cylinders 4 Displacement 153 cubic inches (2505 cm3) Bore X stroke 3,46 x 4,06 inches (88x103 mm) Combustion air consumption 88 cf/m (2,5 m3/min.) Continuous power 50Hz 20 kW Cooling system indirect cooling by raw water, 20-25 l/min. Cooling water pump pto driven Mastervolt self priming impeller pump, type M16 Fuel lift pump engine mechanical pump, additional electric 12V pump available upon request Starting battery (optional) 110 Ah12V Fuel consumption 0,53 - 2 US gallon/hour (2-7 litre/hour), load dependent Control Digital Diesel Control including automatic start/stop

ELECTRICAL SPECIFICATIONS

Output voltage 120/240V 60 Hz alternating current (AC) single phase Output rating 50Hz 20 KVA = 20 kW at power factor cos phi = 1 Voltage tolerance ± 5% (optional voltage regulator ±2%) Frequency tolerance ± 5% Optional electronical Governor ± 1% Alternator brushless, four pole, synchronous Voltage regulation capacitor + AVR (optional)

MECHANICAL SPECIFICATIONS

Supply includes generating set, built into tugged GRP sound shield with steel base plate,

mounted on rubber anti vibration mounts

Dimensions hxwxd 45,28x26,77x29,57 inches (1150 x 680 x 750 mm) Colour top white, bottom green Weight 926 lbs. (420 kg) including canopy Max. installation angle 25 degrees Standard supplies remote panel ± 45 ft. (+15 m cable), fuel filter, fuel lift pump, user and installation

manuals

Optional installation kits, mobile (vehicle) version, non earth return, (ungrounded)

spare part kits, PTO to drive hydraulic pump

2.5.12 Cooling liquid

The engine is cooled by cooling liquid. The capacity of

this system of the Whisper 20 ULTRA is 7,6 US qts (7,2

l).

We recommend not using water but cooling liquid that is

marketed for the use in combustion engines. Cooling

liquid protects the engine against frost until minus 25° C.

Also it protects the engine block against corrosion. One

can fill the engine via the filling cap on the exhaust

manifold. Fill up till the level is just below the filling cap.

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.

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 cal-

culated according to the information of the supplier of the

anti freeze. When the cooling is based on keel cooling or

radiator cooling the capacity of these coolers and piping

has to be taken into account calculating the right mixture.

The cooling liquid in the engine is pressurised and has a

boiling point above 212°F (100° C). The temperature

switch in the thermostat housing switches at 230°F

(110° C). When keel cooling or radiator cooling is applied

the cooling system is not pressurised. There should be a

special cap on the manifold without valves leaving the

connection to the expansion tank open. Refer to the

special manual on keel cooling and radiator cooling.

Page 13

USA / WHISPER 20 ULTRA / May 2003 13

INFORMATION

2.5.14 Wiring codes and colours

number colour AWG cable code no

cross section

STANDARD

battery > starter motor red 2 35 mm2

starter motor > DCC 1 red 10 6 mm2

battery > LCP 13 red 14 2,5 mm2

battery > ground black 2 35 mm2

ground > LCP ground (GND) 2 black 12 4 mm2

DDC > glow plugs 3 brown 12 4 mm2

DDC > starter solenoid 4 yellow 14 2,5 mm2

DDC > LCD 5 grey 16 1,5 mm2

DDC > oil pressure switch 6 purple 17 1 mm2

LCP > oil pressure switch 6 purple/black 17 1 mm2

DDC > water temperature switch 7 blue 17 1 mm2

LCP > water temperature switch 7 blue/black 17 1 mm2

DDC > exhaust temperature switch 8 blue/green 17 1 mm2

LCP > exhaust temperature switch 8 blue/rose 17 1 mm2

DCC > fuel solenoid (hold) 9 green 16 1,5 mm2

DCC > fuel solenoid (pull) 20 grey 14 2,5 mm2

DCC > fuel solenoid (com.) 17 black 14 2,5 mm2

B+ terminal alternator > starter motor 21 red 10 6 mm2

DCC > R terminal alternator 18 wit 16 1,5 mm2

DCC > L terminal alternator 19 orange 16 1,5 mm2

DCC > current measuring transformer 11 black 17 1 mm2

DCC > current measuring transformer 11 red 17 1 mm2

DCC > current measuring transformer 22 black 17 1 mm2

DCC > current measuring transformer 22 red 17 1 mm2

DCC > LCP 12 black 16 1,5 mm2

DCC > LCP 14 red 16 1,5 mm2

DCC > LCP 16 red/green 16 1,5 mm2

DCC > generator AC output 33 brown 17 1 mm2

DCC > generator AC output 33 blue 17 1 mm2

DCC > generator AC output 44 brown 17 1 mm2

DCC > generator AC output 44 blue 17 1 mm2

DDC=Digital Diesel Control Unit

LCP=Local Control Panel

Page 14

14 April 2004 / WHISPER 20 ULTRA / USA

INFORMATION

2.5.15 Lay out control PCB

CONTROL PANEL

TO REMOTE

hold

ct-2

ct-1

ct-2

gnd

tem

str.

exh

oil

reg

alt.

fuel

heat start fuel fail

pull

AC-1

AC-2

8586

LOCAL CONTROL PANEL

J20

PUMP

J21

ALT

REGULATOR

J18 J19 J22

START/STOP

J8 J9

J10

J11

J12

J13

J14

J16

J15

J17

WCH/0

TAILOR MADE ENERGY

ALT-L

MASTERVOLT

10A 3A

10A

ALT

CURRENT MESURING

TRANSFORMER

BLACK (11)

RED (11)

AC-2

AC-1

TO GENERATOR AC OUTPUT

BLUE (44)

BROWN (44)

BLUE (33)

BROWN (33)

TRANSFORMER

CURRENT MEASURING

BLACK (22)

RED (22)

SWITCH

EXHAUST TEMP.

WATER TEMP. OIL PRESS.

SWITCH

SOLENOID

FUEL

WHITE (PULL)

BLACK (COMM.)

RED (HOLD)

GREY 2,5 (20)

GREEN 1,5 (9)

RED/GREEN 1 (16)

PURPLE 1 (6)

BLUE/GREEN 1 (8)

BLUE 1 (7)

ORANGE 1,5 (19)

RED 35

ENGINE BLOCK

GROUND TO

GLOW (PREHEAT)

PLUGS

SWITCH

BATTERY

(OPTIONAL)

PURPLE/BLACK 1 (6) J14

BLACK 35

SOLENOID

BROWN 6 (3)

GLOW (PREHEAT)

BROWN 1.5 (24)

BLACK 4 (2)J17

(OPIONAL)

12VDC

BATTERY

RED 6 (3)

BLACK 1,5 (25) J15

BLACK 2,5 (17) J16

BLUE/PINK 1 (8) J12

BLUE/BLACK 1 (7) J10

WHITE 1,5 (18)

ALTERNATOR

STARTER

MOTOR

RED 6 (21)

RED 2,5 (1)

GREY 1,5 (5)

BLACK 1,5 (12) J8

RED 1,5 (14)

YELLOW 2,5 (4)

RED 2,5 (13)

SWITCH

Fig. 7: Lay out control PCB.

Page 15

USA / WHISPER 20 ULTRA / April 2004 15

STATOR

120-240V 60Hz

ROTOR

EARTH AND NEUTRAL CONNECTED

EARTH AND NEUTRAL NOT CONNECTED

EARTH AND NEUTRAL CONNECTED

DCC/AC-1

BROWN (33)

YELLOW/GREEN

BLUE (33)

120V 60Hz

BROWN

BLUE

YELLOW/GREEN

BROWN

120V 60Hz

TRANSFORMER

BLACK

BLACK (22)

DCC/ct-2

DCC/AC-2

TRANSFORMER

CURRENT

BROWN (44)

BROWN (33)

BLUE (33)

DCC/AC-1

RED (22)

RED

DCC/ct-1

(11) (11)

CURRENT

BLUE (44)

YELLOW/GREEN

BLACK

YELLOW/GREEN

120-240V 60Hz

BLUE

BROWN

DCC/ct-1

(11)(11)

CURRENT TRANSFORMER

BLACKRED

(22) (22)

DCC/ct-2

BLACKRED

CURRENT TRANSFORMER

TRANSFORMER

CURRENT

DCC/AC-1

BROWN (33)

YELLOW/GREEN

BLUE (33)

DCC/ct-1

BLUE

YELLOW/GREEN

RED

DCC/ct-2

(22)

BLACK (22)

RED (11)

BLACK (11)

TRANSFORMER

CURRENT

MAIN WINDING

(4)

MAIN WINDING

(4)

(3)

EXCITATION WINDING

(2)

(1)

YELLOW/GREEN

DCC/AC-1

BROWN (33)

BLUE (33)

BLUE

YELLOW/GREEN

TRANSFORMER

RED (11)

DCC/ct-1

BLACK (11)

CURRENT

CAPACITOR

BROWN

DCC/ct-2

(22)

RED

(22)

BLACK

DCC/AC-2

BROWN (44)

BLUE (44)

CURRENT TRANSFORMER

BLACK

2.5.17 Electrical diagram 230V 50Hz

INFORMATION

Page 16

16 April 2004 / WHISPER 20 ULTRA / USA

2.5.17 Diagram electronic governor (optional)

INFORMATION

Fig. 9:

Page 17

USA / WHISPER 20 ULTRA / April 2004 17

OPERATION

3 OPERATION

3.1 GENERAL

The generating set is operational after full installation and

filling up with: fuel, engine lubricating oil and cooling li-

quid, filling the starter battery with acid, connecting the

battery to earth and connecting the digital remote control

panel.

3.2 OPERATION INSTRUCTIONS

3.2.1 Summarised operating instructions (daily use)

Routine "pre-start" checks:

1Check oil level (refer to fig. 10).

2 Engine cooling system (all valves open).

3 Power source selector switch (off/shore power/gene-

rator power). Switch to power source switch "OFF", or

switch off all consumers in the usual way. If a MAS-

TERSWITCH is installed, this is operating automati-

cally.

4 Switch on battery switch (when installed).

5 Fuel valve: open.

Starting:

Push the start button to initiate the full automatic

starting procedure. You can monitor the procedure on

the display.

In operation checks:

1 Check for abnormal noise or vibration

2 Check the voltage

3 Check sea water flow at exhaust outlet

4 Power source selector switch (off/shore power/gene-

rator power). Switch to power source generator. If a

MASTERSWITCH is installed, this is operating auto-

matically.

5 Before loading the generating set up to maximum,

have it run warm. Continuous load should be restric-

ted to 70 % of maximum load.

Stopping generator:

1 Switch off all electrical devices (consumers). If the

generating set has been running under full load for a

longer period, do not shut it down abruptly. Reduce

the electrical load to about 30% of the rated load and

let it run for approx. 5 minutes.

2 Press the STOP button.

3 Close the inlet sea water cock.

4 Switch to another AC power source, if available. If a

Masterswitch is installed, this is done automatically.

3.2.2 Extended operating instructions

Check when starting the first time or after a longer period

of rest:

1 If there is any damage caused by transport or instal-

lation.

2 Check if installation conforms with the installation

instructions.

3 Ensure the generating set is free to turn without ob-

struction.

4 Check all hoses and hose connections for leaks.

5 Check all cables and cable end terminal connections.

6 Check the engine and generator mounting bolts.

Routine "pre-start" checks:

1 Check engine oil level.

The generator switches off in case of insufficient oil-

pressure. Even when the oil level is too low the oil

pressure can be high enough. Do not run the

generator with the oil below the lowest mark, because

a smaller volume of oil will become contaminated

considerably quicker than a larger volume. Therefore

we recommend daily oil-checks.

Check oil level prior to starting the engine, or at least

5 minutes after the engine has stopped.

1 2

Fig. 10.

1 Max. oil level;

2 Min. oil level.

Page 18

18 April 2004 / WHISPER 20 ULTRA / USA

OPERATION

2 Check sea water cocks. Do not forget the valve of the

water outlet in case of a water/exhaust gas separator.

3 Check the water strainer.

4 Check for leakage’s.

5 Regularly check the siphon vent in the cooling water

supply.

6 If no MASTERSWITCH is used: Switch main Power

Source Selector switch to "OFF" or switch off all de-

vices.

7 Switch on the battery switch.

Starting the generator:

By pushing the start button briefly the electric system

is activated, the fuel lift pump starts pumping and the

starting procedure will begin. (By pushing the stop

button the system is deactivated). The first time

starting up or after running out of fuel it could be

necessary to prime the fuel system. (Refer to

bleeding fuel system instructions in the maintenance

chapter).

A restart protection prevents for starting the engine while

already running which could cause damage.

In the event of starting problems (nume-

rous attempts are made), close the sea-

water inlet cock while cranking to prevent

the outlet system and engine to fill up with

water.

During the starting process, the cooling water pump is

driven with the engine. The cooling water is discharged

to the exhaust outlet, since the engine does not run, the

exhaust pressure is not high enough to expel this water.

Open the valve directly when the engine starts to prevent

for damaging the impeller.

Water in the cylinders will cause serious damage to the

engine. For instance; a bent piston rod or a cracked cylin-

der head. In fact water in the cylinders is the main cause

for engine damage in pleasure craft.

Checks once the generator is in operation:

1 Check for abnormal noise or vibration.

2 Check the voltage.

3 Check coolant flow.

Always check immediately after starting the generator

if cooling water flows at the exhaust outlet. If this is

not the case, check the cooling water pump. After

having become acquainted with the generator you will

be able to recognise the coolant flowing through the

system by listening for the noise of the water which is

expelled.

Be aware that especially in harbours the

coolant water inlet can easily be blocked

by floating objects.

4 Power source selector switch (off/shore power/gene-

rator power). Switch to power source generator. If a

MASTERSWITCH is installed, this is operating auto-

matically.

Before loading the generating set up to maximum,

have it run warm. The first 50 hours of running the

continuous load should be restricted to 70 % of maxi-

mum load. Running for long periods at no load or light

load in the first 50 hours can cause cylinder glazing

and high oil consumption.

Engine load during longer operation:

Please ensure that the generating set is not overloaded.

Overloading occurs when the electrical load (demand) is

so high that the generator cannot be turned around

properly by the diesel engine. Overloading causes the

engine to rum rough, while using oil and excessive fuel

and producing soot by the exhaust. The engine can even

stop.

The generator should therefore only be loaded at the

maximum rated power for short periods (2-3 hours) only!

The high peak current is meant for the ability to start

electrical devices, that need a high current for starting

especially electric motors and compressors (from a still

stand state).

In order to prolong the generating set’s life expectance,

the nominal electrical demand on the system should be

about 70% or the rated generating set’s maximum load.

Please note this when switching on your electrical

devices!

Nevertheless, the Whisper is designed so as not to

overheat, even under extreme conditions.

Never remove the battery while the engine

is running, or any electrical cable while the

battery is connected in the circuit. Only

disconnect the battery with the engine

stopped and all switches in "OFF" position.

Stopping the generating set:

1Avoid stopping of the generator abruptly after a long

period of operation at high load! Doing so, you avoid

Page 19

USA / WHISPER 20 ULTRA / April 2004 19

unnecessary thermal load to your generating set!

Act as follows:

Prior to switching off the generating set, decrease the

generator load (i.e. turn off most electrical users) and

let the generator run at low load for approx. 5 minutes

to allow the engine to get properly cool ( the influent

sea water must flow through the system in order to

cool the engine).

If the generator is operating in a hot environment and

you do not act as given above, the excessive heat in

the engine can trip the "high temp" alarms. In that

case, a restart of the engine is not possible for some

time. It is also recommended to switch off electrical

users prior to stopping the generator. Because of the

voltage drop that occurs as the engine comes to a

halt. Such voltage drops may cause damage to elec-

tric motors, compressors (in refrigerators or air condi-

tioners etc.).

2 Press the STOP button.

3 Close the inlet sea water cock.

4 Switch to an other AC power source, if available. If a

Masterswitch is installed, this is done automatically.

If the engine is not running and failure and

charging LED is blinking, reset by stop but-

ton, otherwise it will drain the start battery.

OPERATION

Page 20

20 April 2004 / WHISPER 20 ULTRA / USA

MAINTENANCE

4 MAINTENANCE

4.1 ALTERNATOR

The alternator does not require any maintenance. Perio-

dic inspection and cleaning is recommended, depending

on environmental conditions.

However when the alternator has been idle for a long

period attention to winding condition is recommended.

The condition of windings can be assessed by measure-

ment of insulation resistance to earth.

The CAPACITOR should be disconnected during this

test. A 500V ‘Megger’ or similar instrument should be

used. The insulation resistance to earth of all windings

should be in excess of 1.0 MOhm. Should the insulation

resistance be less than this value, drying out the genera-

tor windings is essential. Drying out can be carried out by

direct warm air from a fan heater or similar apparatus into

the generator air inlets or outlets.

All bearings are greased for life and not regreasable.

4.2 ENGINE

4.2.1 Preliminary instructions

All regular maintenance can be executed when the en-

closure is open. When oil and dirt has gathered in the

enclosure measures has to be taken to avoid spilling oil

and polluting the environment.

The first service on the engine should be carried out after

50 hours of its life and after a major overhaul. In the first

50 hours the engine should receive special attention:

Long periods of light or no load running in the first 50

hours may lead to cylinder glazing and high oil consump-

tion.

For the same reason it is of the greatest

importance to use the right oil specifica-

tion.

The first time starting up or after running out of fuel it

could be necessary to prime the fuel system.

4.2.2 Bleeding fuel lines

Ensure there is sufficient fuel. The Whispers are self

bleeding. To check the well functioning release the

bleedscrew on the high pressure fuel pump. Turn loose

the cap of the fuel lift pump and move the piston up and

down to prime the system. Retighten the bleed screw

when no further air bubbles are expelled. Retighten the

cap when ready.

4.2.3 Valve clearance

When the engine is in cold condition both valves should

have a clearance between 0.25 mm. The adjustment has

to be done at TDC (refer to § 5.4.2).

4.2.4 Replacing fuel filter

Filter change depends on contamination of the fuel, but

should be done however, at least every 300 running

hours. A clogged filter results in a lack of output of the

generating set. (Refer to fig. 13)

4.2.5 Replacing the oil filter

The oil filter is in front of the service side. Replacement

has to be executed according to the schedule in this

manual. Drain the oil using the sump pump and put some

tissues under the filter.

1 = Fuel bleeding screw

2 = Cap fuel lift pump

Fig. 11: Bleeding fuel lines.

Fig. 12.

Page 21

USA / WHISPER 20 ULTRA / April 2004 21

A smeer of oil has to be put on the seal of the filter before

fitting the filter. The filter should be fastened manually:

when the rubber touches the metal turn 3/4 further.

4.2.6 Readjustment V-belt

The alternator bracket allows to readjust the V-belt. De-

flections should be 10 mm (refer to fig. 14).

4.3 REGULAR MAINTENANCE

CHECK DAILY:

• Oil level (see fig. 15)

Take care the oil level is never

below the mark. Do not add oil

when the level is still above the

mark.

CHECK DAILY:

• Level cooling liquid.

• Hoses for loose connections or deterioration.

•Water inlet filter.

AFTER FIRST 50 HOURS:

• Change oil and replace the oil filter.

Have the engine run until it is on temperature and

stop it. Drain oil by the sump pump into a suitable

retainer and fill up with fresh oil. Start the engine

again and have it run for 5 minutes. Stop the engi-

ne again and pause for a few minutes to let the oil

gather in the crankcase. Check the level again

and add oil when necessary.

• Check and tighten nuts, bolts, and unions, paying

particular attention to the fuel system.

• Retighten the cylinder head bolts and adjust the

valve clearance. (Refer to paragraph 5.4.2)

• Observe the exhaust at the normal full load. The

exhaust must be free from soot. Do not allow the

engine to run with a dirty exhaust without investi-

gating the cause as this may result in an expensi-

ve breakdown.

•Check the air vent on a regularly basis.

When the air vent it not working properly the en-

gine can fill up with water by siphoning. Water in

the combustion chamber causes serious damage

to the engine.

• Check and readjust V-belt.

EVERY 100 HOURS:

• Change oil.

• Check the battery acid level.

• Check battery terminals for corrosion

• Check and readjust V-belt.

• Check impeller raw water pump (durability de-

pends on the purity of the sea water. In sandy wa-

ter and warm water wear out will increase).

When replacing the impeller the gasket between the

pump case and the cover should be replaced as well.

So when ordering a spare impeller, order a gasket as

well. Remove the cover to get access to the impeller. Re-

move the old impeller with the help of two screwdrivers.

Install the new impeller and add some grease. Turn the

blades in the direction of rotation of the pump.

10 mm

Fig. 14.

1 2

1 Max. oil level;

2 Min. oil level.

Fig. 13.

Fig. 15.

MAINTENANCE

Page 22

22 April 2004 / WHISPER 20 ULTRA / USA

MAINTENANCE

EVERY 300 HOURS:

• Replace the impeller of the raw water pump.

• Check valve clearance.

• Replace the oil filter.

• Replace the fuel filter

Replacement depends or the condition of the fuel.

We recommend replacement every 300 hours.

Isolate the fuel supply and change the element.

EVERY 1000 HOURS:

• Replace the V-belt.

• Retighten cylinder head bolts/adjust +

valve clearance.

EVERY 2000 HOURS:

• Check lubricating oil pressure

• Clean and check or replace fuel injector nozzles

and check injection pressure.

• Check the air filter element:

The air is taken in via the cover on the alternator.

Below this cover is a spongy material which filters

the air and holds some electrical components

which are cooled by the inlet air. This filter does

not require regular maintenance. Only in very

dusty circumstances this filter should be cleaned.

The spongy material can be washed in solvent or

replaced.

• Check the cooling system:

The engine cooling liquid is indirectly cooled by

raw water via a heat exchanger. The alternator is

cooled by seawater which is pumped by the PTO

driven impeller pump through the cooler elements

in the generator housing. All parts of the cooling

system are of corrosion free and seawater resis-

tant materials such as naval brass and gunmetal.

In case of gathering of dirt in the system it could

be cleaned by compressed air. When overhauling

the engine one could clean the parts thoroughly or

replace.

When the generator set runs less than 100

hours a year the oil should be changed

yearly.

4.3.1 Maintenance schedule

4.3.2 Putting out of service

When not using the generator for a longer period it is re-

commended to execute an engine preservation procedure.

1 Clean the engine.

2 Loosen the fuel suction pipe and fuel return and put

them in a can with preservation diesel fuel. Start the engine and run the engine warm.

3 Drain the hot engine oil and refill with preservation oil.

4 Stop the engine and take loose the inlet of the raw

water pump. Drain the water from the water lock. Crank the engine having the raw water inlet sucking anti freeze from a can until the pump, heat exchanger and manifold are filled.

5 The coolant can stay in the engine.

6 Disconnect the battery and stock it in a place dry and

free of frost and charge it regularly.

7 Close inlet- and outlet openings with tape.

8 Protect the generating set against the influences of

bad weather conditions.

This way of preservation will be sufficient for 6 months.

Repeat step 2, 3, and 4, every 6 months. Change oil

before using the engine again.

Check oil level daily

Check water strainer daily

Check the level of the cooling liquid daily

Retighten cylinderhead bolts , change oil, replace oil filter

and read just valve clearance after first 50 hours

Changing oil 100 hours

Checking air vent 100 hours

Check and readjust V-belt 100 hours

Checking impeller water pump 100 hours

Replace the oil filter 300 hours

Replace impeller waterpump 300 hours

Checking valve clearance 300 hours

Replacing fuel filter 300 hours

Retighten cylinder head bolts, adjust valve

clearance 1000 hours

Replace the V-belt 1000 hours

Check injector and injection pressure 2000 hours

Check inlet air filter 2000 hours

Page 23

USA / WHISPER 20 ULTRA / April 2004 23

TROUBLE SHOOTING

5 TROUBLE SHOOTING

5.1 ALTERNATOR/ ELECTRICAL FAULTS

Take care for parts which are live!

Remove 3 Amp. fuse in the control panel

while working on the generator to prevent

the engine to start.

5.1.1 General

If any problem should occur check basic conditions and

examine all external wiring, switch gear and circuit

breakers. Also check if measuring instruments give the

correct value. If in doubt measure direct on the alternator

terminals with an independent instrument.

This should only be carried out by an experienced

electrician.

Check if the engine is running correctly at 1800 RPM (60

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

A RPM drop of 5% at full load is acceptable. Therefore a

no load setting should be at 1875 RPM = 62.5 Hz . Under

no circumstances the RPM under full load should be

below 1770 RPM = 59 Hz.

When the problem is in the RPM refer to the engine fault

finding paragraph.

Digital Diesel Control system will help to indicate failures

and display causes.

5.1.2 Trouble shooting table

PROBLEM CAUSE SOLUTION

No output (voltage) at all. • Circuit breaker "off" or faulty fuse Check switches and fuses and measure direct-

ly on the alternator to exclude external causes.

• Low engine RPM. Check the engine RPM and adjust (refer to special procedures).

• Loss of residual magnetism. Check the residual magnetism and flash the alternator (refer to special procedures).

• Capacitor loose or broken. Check by independent excitation if the problem is in the capacitors or in the windings.

• Rotor diodes broken. Check the diode in the rotor (refer to special procedures) The Whisper 20 ULTRA has one diode in the rotor.

Generator output voltage too • No load at all or very low load. Switch on a load and check voltage. low when no load is on it • Engine is not reaching the rated RPM. Refer to special procedures to readjust RPM. (less than 210V). • Defective capacitor. Check capacitor and replace if necessary (refer

to special procedures).

• Defective diode (one of the two) Check the diodes in the rotor and replace (refer to special procedures).

Generator output voltage too • Generator is overloaded. Switch on a load. low under load (less than • Engine is not reaching the rated RPM. Switch off a load; (part off ) consumers. 210/105V)In no load condition Refer to engine RPM problems. it is ok. • Defective capacitors. Check capacitors and replace if necessary (refer

to special procedures).

• Defective voltage regulator (optional) Replace voltage regulator.

Generator voltage too high, • Engine is running too fast (RPM too high). Check engine speed and adjust (refer to special (more than 250/130V). procedures).

• Over-energising due to defective Check capacitors specification and replace if

capacitors. necessary.

• Presence of a strong capacative load Compensate for this capacity and seek for experts

(leading power factor). advice.(MASTERVOLT customers service).

• Defective voltageregulator Replace voltage regulator

Page 24

24 April 2004 / WHISPER 20 ULTRA / USA

TROUBLE SHOOTING

PROBLEM CAUSE SOLUTION

Generator voltage fluctuates. • Disturbances on the electrical system/ Check if electrical load is fluctuating.

user side.

• Engine runs irregular. When engine runs irregular refer to section: "Engine runs irregular" in engine faults.

Generator is not able to start If the generator is unable to supply enough Check the electric motor’s current draw required an electric motor. power to start an electric motor, for starting. This should not exceed 70% of the

this is usually because this motor draws rated generator peak output current. This could be too much current during starting. remedied by providing stronger capacitors to the

motor or using a "soft-start". Inquire at your nearest Mastervolt dealer or directly at the manufacturer, Mastervolt in the Netherlands.

5.2.2 Trouble shooting check list engine

PROBLEM CAUSE SOLUTION

Diesel engine fails to crank, Almost certainly this is an electrical problem Check on water in the cylinders and further the starter makes clicking or the engine is blocked by water in the damage by cranking. When there is water in the noises, or the engine cranks cylinder or there is other severe damage. cylinder, then deactivate the control system, very slowly. deconnect the battery, remove the glow plugs.

Crank the engine to remove the water through the opening of the glow plugs. Check oil on the presence of water and change oil. Find out how the water did enter the cylinders (check the air vent). Take precautions to prevent it from happening again. When there is no mechanical malfunction the problem must be an electric malfunction.

5.2 ENGINE FAULTS

Remove 3 Amp. fuse in the control panel

while working on the generator to prevent

the engine to start.

5.2.1 General

Most electrical problems relating to Voltage or Frequency

are due to wrong engine speed.

Note that RPM and Hz are basically the same.

Use the problem solving table to find the cause of a

wrong engine speed. When there is no obvious cause

one can adjust the RPM (refer to special procedures).

When the engine is not cranking well, starting problems

almost always originate from battery problems or poor

battery cable connections.

When the engine is cranking well starting problems

almost always originate from lack of fuel or air bubbles in

the fuel pipes.

When the engine does not start instantly,

prolonged cranking can fill up the exhaust

system with cooling water because of the

water injected exhaust. When the water

enters the cylinders through the valves this

will bring severe damage to the engine.

When the engine does not start and

repeated cranking is necessary shut off the

seawater inlet. Open the valve immediately

after the engine has started.

A failure code is displayed when a hardware failure at the

generator is detected.

failure code problem

COMMUNICATION Communication error between the

panel end the generator

LOW START BAT Starter battery voltage too low

ALTERNATOR No output battery charging voltage

EXHAUST TEMP Exhaust temperature is too high

WATER TEMP Coolant temperature is too high

OIL PRESSURE Oil pressure failure

LOW VOLTAGE Generator AC output voltage is too low

HIGH CURRENT generator is in overload

FREQUENCY output frequency of the generator is too

low

Page 25

USA / WHISPER 20 ULTRA / April 2004 25

PROBLEM CAUSE SOLUTION

• Starter battery switched "OF". Check position of the battery switch and switch "ON".

• Starter battery voltage insufficient Check battery voltage. Recharge the battery.

(battery too weak). Inspect battery terminals and cables for a good

electrical connection (inspect against corrosion,

tattered wires, etc.)

• Faulty fuse on control panel. Replace fuse

• Wiring control system faulty. During the normal starting process, the battery voltage drops to 11V (with a fully charged battery). If the voltage does not drop during starting, the electrical connection is faulty. If the battery voltage drops lower than 11V, then the battery has been discharged too deep.

• Starter broken. Repair the starter motor.

• To thick engine lubricating oil. Change oil for a lower viscosity.

Starter is cranking engine • Out of fuel or faulty fuel, water in the fuel. Fill up with fuel or replace by better quality. smoothly, but engine fails • Fuel solenoid is not opening. Check wire connections and circuitry to solenoid. to start. (Refer to DC wiring diagram).

• Fuel lift pump is not working. Check fuel filter and fuel lift pump: clean or

• Fuel filter is blocked. replace if necessary.

• Air in fuel lines. Bleed air from fuel system (refer to maintenance section).

• Wrong valve clearance. Adjust valve clearance.

• Low compression because of dirty valves. Clean valves. Take off the injection bent and inspect the outlet port. When little rust is in the port one can clean the valve by taking of the valve spring and rotate the valve. When the outlet port is strongly affected by rust, the exhaust system is not properly installed. Water has entered the exhaust port or backpressure is too high. (refer to paragraph 5.4.3) Contact Mastervolt service department for advice.

• Blocked injector. Have the injector tested and cleaned if necessary.

• Loss of compression by wear out Repair by Mastervolt service.

or damage

Engine runs irregularly. • Unsuitable contaminated fuel Fill up with fuel or replace by better quality.

• Lack of fuel.

• Choked fuel filter. Check fuel filter and fuel lift pump: clean or replace if necessary.

• Faulty fuel lift pump. Check and repair.

• Choked air filter. Check the air intake.

• Lack of air.

• Choked exhaust system, exhaust blocked, Check the exhaust hose.

rubber exhaust hose kinked.

• Air in the fuel pipes. Bleed air from fuel system (refer to maintenance section).

• Blocked injector. Have the injector tested and cleaned if necessary.

• Wrong valve clearance. Adjust valve clearance.

• Temporarily hunting (this will disappear when engine has run in).

Engine speed drops. • Too much oil. Drain oil to proper level.

• Lack of fuel. Check fuel supply system: fuel pump and filter.

• Lack of intake air. Check air intake.

TROUBLE SHOOTING

Page 26

26 April 2004 / WHISPER 20 ULTRA / USA

TROUBLE SHOOTING

PROBLEM CAUSE SOLUTION

• Choked exhaust system, exhaust blocked, Check the exhaust system. rubber exhaust hose kinked.

• Generator overloaded. Reduce the electrical load (switch off some

consumers).

• Generator over energised. Check that the proper capacitors type are

installed and that they are connected correctly.

• Defective generator (windings, bearings, Generator must be sent to manufacturer for repair or other). of damaged bearing or winding.

• Damaged engine. Repair by Mastervolt service.

Faulty Digital Diesel Control or stop solenoid. Engine does not stop • Fuel solenoid is not switching off. Stop the engine manually by the stop handle. on command. • Loss of control Check wire connections to solenoid.

Replace if necessary.

Engine exhaust smokes • Faint blue smoke - Increase load.

generally the result of light load

• Heavy blue smoke - Check the oil level. caused by lubricating oil: Check the compression. Overfull oil sump or worn cylinder bore, stuck broken or worn rings.

• Black smoke - Check the fuel . incomplete combustion caused by: Check for overload.

Overload, choked air filter, inlet temperature

too high, unsuitable fuel or water in fuel.

Display will help to identify failures Engine starts, but stops • Protection system stops the engine; Refer to paragraph 2.5.5. and 3.2.2 for after 10 up to 30 seconds this can be caused by oil pressure information on the alarmsystem. Bypassing the

failure, lack of coolingwater switches can help to identify the failure. (exhaust temperature alarm) Loose wire or faulty alarm switch.

Display will help to identify failures Engine stops by itself. • Overload or short circuit. Switch off the consumers and test for short circuit.

• Lack of fuel. Check fuel supply system: fuel lines, pump, filter, valves, tank level, etc.

• Oil pressure low.(oil pressure switch Check oil level.

tripped). Check engine’s oil pressure and have it repaired

by Mastervolt.

• Excess heat in cooling system Check cooling water system flow: water pump,

(thermo-switch tripped). inlet water filter, coolant flow.

• Lack of cooling water (exhaust

switch tripped).

• Impeller broken.

• Cooling water blocked.

• Water strainer blocked.

• Air or water in the fuel.

• Blocked air or fuel filter.

• Loss of compression by wear out Repair by Mastervolt service.

or damage.

• V-belt broken or loose Readjust or replace V-belt.

• Thermostat faulty Check thermostat and replace.

Sooty, black exhaust. • Generator is being overloaded. Check electrical load and switch off some

Display will indicate “overload” consumers.

• Insufficient intake air. Check intake air paths and filter, clean and

• Choked air filter. replace if necessary.

• Fuel injector faulty. Replace injector.

• Valve clearance incorrect. Readjust valve clearance.

Page 27

5.2.3 Warnings

Generator must be shut off immediately if:

• Motor RPM suddenly rises or drops.

• Unusual noise comes from generating set.

• Exhaust gases suddenly colour dark.

• Engine failure warning light is on

5.2.4 Service address

If you cannot correct a problem with the aid of the mal-

function table, contact your Mastervolt Service Centre or

Mastervolt Amsterdam for an extended service list, tel:

INT +31-20-3422100. www.mastervolt.com

5.3 SPECIAL PROCEDURES ALTERNATOR

5.3.1 Residual voltage check / excitation procedure

When residual magnetism disappears there is no resi-

dual voltage. Residual magnetism can disappear after

the generating set being a long period out of service or a

short circuit. This can be solved by charging the capa-

citor ("flashing") independently by a small 9 Volt battery.

This can be done while the engine is stationary and the

wiring is connected.

If the starter set battery is used for flashing

one must take care. A short circuit can

cause heavy sparking, fire and injuries.

When flashing does not bring back voltage, the capaci-

tor(s) should be renewed. When this does not help, the

rotating rectifier diode should be tested and a winding re-

sistant test should be executed.

5.3.2 Testing rotary rectifier diode

The diode in the rotor can be checked with a multimeter.

When the diode is faulty, the alternator will not generate

any voltage.

USA / WHISPER 20 ULTRA / April 2004 27

PROBLEM CAUSE SOLUTION

• Poor fuel quality. Use better quality diesel.

• Poor quality lubricating oil. Use better quality oil.

• Continuous running with very low load. Increase load and have the engine run for a few hours.

Loss of power

• Wrong measurement. Check if the load is measured correctly. Does the Amp meter show the

correct value? When calculating the load by multiplying voltage and amps this should be done by using the exact values, taking into account the power factor of the consumers. When any doubt measure the power directly with an appropriate instrument.

• Overfull oil sump. Bring the oil to the correct level.

• Choked full filter. Replace the fuel filter.

• Choked air filter. Check air inlet openings; clean air filter.

• Exhaust blocked. Check the exhaust system.

• Injector blocked. Have the injectors checked.

• Loss of compression, sticking or Have the compression measured.

damaged piston rings. Clean or replace the rings.

• Wear out of cylinders. Have the compression measured and have the engine overhauled.

Over-temperature • Overload. Take away the overload.

• Low level of cooling oil or Fill up with liquid and release air bubbles.

• air in the cooling system. Check if there are air blocks in the system; refer to the installation manual.

• Water inlet system blocked. Check the cooling system thoroughly

• Broken impeller.

• Water strainer choked.

• Heat exchanger choked.

• Broken or slipping V-belt. Replace and adjust the V-belt tension.

• Faulty thermostat. Check the thermostat or replace.

Fig. 16.

TROUBLE SHOOTING

Page 28

28 April 2004 / WHISPER 20 ULTRA / USA

TROUBLE SHOOTING

The flexible lead connected to the diode should be dis-

connected at the terminal end, and the forward and

reverse resistance checked. A healthy diode will indicate

a very high resistance (infinity) in the reverse direction,

and a low resistance in the forward direction. A faulty

diode will give a full deflection reading in both directions

with the test meter on the 10,000 ohms scale, or an

infinity reading in both directions. Replace the diode.

5.3.3 Winding resistant values

If after establishing and correcting any fault on the

capacitor and diodes output is still low when separately

excited, then the main rotor, stator and exciter stator

winding resistance should be checked as the fault must

be in one of these windings. The respective leads must

be disconnected before taking the readings.

Resistance values should be within 10% of the values

given in the table below:

Resistance Whisper 20 ULTRA 60Hz-240V

• Resistance both main stator windings 0.15 Ohm

in series

• Resistance both rotor windings 3,90 Ohm

• Resistance exciter stator winding 0,36 Ohm

5.3.4 Meggering

One can try to measure resistance between the housing and

the windings by a multimeter which should read infinitely.

When readings indicate infinity but a fault is suspected

one can do a high voltage resistance test (MEGGERING)

This procedure should be carried out by an expert

5.4 SPECIAL PROCEDURES ENGINE

5.4.1 Setting the RPM

RPM is set by the manufacturer and should not need

readjustment! However a very slight offset after running

in could occur. RPM can be measured by a frequency

meter. Before readjustment check any other explanation

for the wrong speed. Engine speed is set at the factory

at nominal 1800 RPM (60 Hz). A RPM drop of 5% at full

load is acceptable. Therefore a no load setting should be

at + 1875 RPM = 62.5 Hz.

Under no circumstances the RPM under full load should

be below 1770 RPM = 59 Hz. When no cause can be

found for a wrong speed, the setting can be adjusted:

It is very important to identify the correct setting assem-

bly (refer to fig. 18).

The screw is to be locked in position with the lock-nut.

5.4.2. Adjusting valve clearance and retightening the

cylinder head bolts.

Both procedures has to be executed with a cold engine.

When both procedures are executed be sure to retighten

the cylinder head bolts before adjusting the valve clea-

rance.

When retightening the cylinderhead bolts, drain the coo-

lant by removing the drain plug (ref. to fig. 2).

Loosen the bolts slightly, remove the rocker assembly

(the rocker arms, shaft, and stays) and then retighten the

bolts to the specified torque in the numerical order

illustrated (ref. to fig. 19).

Tightening torque cylinder head bolt: 118 ± 5 Nm

Rocker stay tightening torque: long bolts 15 ± 2 Nm

short bolts 12 ± 1 Nm

Front engine

The clearance of both valves intake and exhaust should

be 0.25 mm in cold condition. Set the piston of the first

cylinder to be adjusted to top dead centre (T.D.C.) of

compression stroke.

The T.D.C. of compression stroke can be found by

aligning the T.D.C. mark -0- on the crankshaft pulley with

the mark on the gear case (ref. to fig. 20).

First align the T.D.C. mark for the No. 1 cylinder. Confirm

that the valves do not move up or down when the

Fig. 18.

2= adjustment screw RPM

Fig. 19.

DIODE

Fig. 17.

Page 29

USA / WHISPER 20 ULTRA / April 2004 29

crankshaft is turned about 20 degrees in normal and

reverse direction of rotation.

If the rocker arms move piston no.1 is on the T.D.C. of

the intake or exhaust stroke. In such case turn the

crankshaft 360° in the direction of engine rotation again.

No. 1 piston is now at T.D.C. of the compression stroke.

After adjusting the valves of cylinder 1 adjust the valve

clearance of the remaining cylinders in firing order: 1-3-4-

2. Turn the crankshaft 180 degrees clockwise from the

T.D.C of cylinder 1 to the T.D.C of cylinder 3. Adjusts the

valves of cylinder 3 and turn the crankshaft 180 degrees

further clockwise to the T.D.C of cylinder 4 and adjust the

valves. And again 180 degrees to adjust 2.

5.4.3 measuring exhaust backpressure

The exhaust system must be of adequate size -

2”/ 51 mm - and maximal length (refer to installation

manual). When any doubt; backpressure has to be

measured. An easy way to measure for back-pressure is

to use a water column.

A water column can be made visible in a plastic tube

along a yardstick and fitting the end to a hose connection

to fit in the adaptor on the injection bent after removing

the exhaust temperature switch.

The bent A hanging down should not be to short helping

to damp the pulsating effect of the gas discharge. The

water column should be no more than 27 inches (69 cm.)

of water (1 PSI - 0,07 bar)

5.4.4. Disassembling instructions

It could be necessary for repair or checks to disassemble

the generating set.

Following instructions will help:

1 The design of the Whisper 20 makes it possible to do

most repairs on the spot. The heatexchanger is

accessible and can be removed. The connections of

the alternator are very accessible as well. The same

is true for the diode of the rotor.

2To take the generating set out of the canopy all hose

and cable connections has to be taken off. The set is

fixed to its base by four rubber mountings and can be

taken loos by removing the four nuts from the bolts of

this mountings. Moreover the generating set is fixed

by 2 fail safes that prevents the generating set of

getting loose when the rubber mountings would break

down. The nuts of the fail safes are diagonal to each

other. When the 6 nuts in total are removed the

generating set can be lifted out the canopy.

3 The easiest way to get the generator out of its cap-

sule is by lifting the set with aid of the lifting eyes and

take away the capsule downwards.

4 The cooler elements are welded to the alternator hou-

sing with silver and cannot be disassembled. However

one can take off the complete alternator housing.

5 Before the alternator can be taken off one has to take

out the fitting to the heatexchanger to be able to take

off the metal cover. All cables and wiring has to be

taken loose first.

6 The rotor can be taken off by removing the bold which

goes through the shaft (normal clockwise threaded).

The end of the shaft is specially threaded to push off

the rotor from the conic stub shaft, which is on the

flywheel, using a 0,39 inch (10-mm) rod of 10,6

inches (270 mm) length and a M24x2 bolt.

7 Reassembling the generating set one should take

care for alignment cleaning the surfaces between en-

gine and alternator and tighten the bolds crosswise

and gradually.

8 Use Loctite 577 to seal the fittings, which should first

be cleaned and made free of oil and grease.

9Test the generating set first outside its capsule and

check very carefully for leakages before putting it

back in its enclosure.

Fig. 21: Measuring exhaust backpressure

TROUBLE SHOOTING

Fig. 20.

Page 30

30 April 2004 / WHISPER 20 ULTRA / USA

SPARES

6 SPARES

A complete parts manual in English is available as an option number: 50200184. (***)

A work shop manual in English is available as an option number: 50200173. (***)

We recommend the following spares for service and maintenance.

• Kit A: parts for regular maintenance parts marked (*) article no 50201360

• Kit B: parts for maintenance + spare parts: all parts market (*)+(**) article no 50201361

• Kit C: parts for "world travellers" all parts market (*)+(**)+(***) article no 50201362

ARTICLE NO DESCRIPTION

50206122 Fuel filter (*) 50206120 V-belt (*) 50206121 Oilfilter (*) 50201350 Raw water pump complete Mastervolt type M16 (***) (refer to fig. 22) 50206254 Impeller + gasket (*) (8+14) 50206255 Cover type M16 (**) (10) 50209018 Bolts cover (**) (1) (6 pcs.) 50206257 Repair kit A consisting of: Shaft (6+9+12), Bearings (2 pcs) (7), O-ring (17), Seal (5), shim (13)

Ring (15), Cam (4), screw (2+3), screws (11), cover (10) 50206258 Repair kit B (**)(7+17+5+15) 50201323 Heat exchanger complete with appendages (***) 50201322 Water hoses with clamps (**) 50201060 Capacitor xx micro-farad, 2 pcs (**) (xx = give value when ordering) 50209132 Measuring coil (***) 50201890 Rotary diode (**) 50201482 Alternator bearing including O-ring (**) 50209140 Voltage regulator (optional) 50209104 Local control panel (***) 50209100 Digital Diesel Control unit (***) 50212170 Fuses 10 Amps(*) 50212154 Fuses 3 Amps (*) 50201366 Wiring loom complete (***) 50209102 Digital Diesel remote control panel (***) 130010915 Cable remote control 45 ft. (15 mtr), including connectors 50206033 Overhaul gasket kit / Sealkit (***) 50206030 Cylinder head gasket kit 50206040 Glow plug, 4 pcs (**) 50203050 Nozzle injector, 4 pcs (**) 50206045 Thermostat (**) 50206038 Gasket thermostat (**) 50206034 Gasket rocker cover (**) 50109051 Silicone O-ring soundshieldcover (**)

More extensive parts list on the internet: www. mastervolt.com (fast moving parts)

Page 31

USA / WHISPER 20 ULTRA / April 2004 31

SPARES

Spare parts Raw water pump M16, article no 50201350:

no description article no

1 Pump housing M16 50206261

2 Screw cam pump M16 50206265

3 Gasket washer pump M16 50206274

4 Cam pump M16 50206269

5 Seal pump M16 50206262

6 Shaft pump M16 50206267

7 Bearing pump M16 (2x) 50206264

8 Impeller, pump M16 50206259

9 Coupling shaft pump M16 50206268

10 Cover pump M16 50206255

11 Screw cover waterpump 50209018

12 Spring pin shaft pump M16 50206272

13 Shim pump M16 50206271

14 Gasket pump M16 50206260

15 Ring pump M16 50206266

16 Pin shim pump M16 50206270

17 O-ring pump M16 50206263

Impeller kit pump M16 (8+14) 50206254

Repair kit A pump M16 (6+9+12+7+17+

5+13+15+4+2+11+10) 50206257

Repair kit B pump M16 (7+17+5) 50206258

Fig. 21: Water pump type M16

Page 32

32 April 2004 / WHISPER 20 ULTRA / USA

MAINTENANCE LOG

first service after 50 hours: hour counter: remarks:

next service (every 150 hours) hour counter: remarks:

Page 33

USA / WHISPER 20 ULTRA / April 2004 33

NOTES

Page 34

34 April 2004 / WHISPER 20 ULTRA / USA

NOTES

Page 35

USA / WHISPER 20 ULTRA / May 2003 35

NOTES

Page 36

36 April 2004 / WHISPER 20 ULTRA / USA

MASTERVOLT

Snijdersbergweg 93, 1105 AN Amsterdam, The Netherlands

Tel.: +31-20-3422100 / Fax: +31-20-6971006

www.mastervolt.com / info@mastervolt.com