Mastervolt Whisper 3.5 3000 RPM, Whisper 3.5 User Manual

USERS MANUAL

WHISPER 3,5

- 3000 RPM -

Marine diesel generating set 230V / 50Hz

Digital Diesel Control

MASTERVOLT
Snijdersbergweg 93,
1105 AN Amsterdam
The Netherlands
Tel.: [phone]
Fax.: [phone]
www.mastervolt.com

V5. May 2006

Art.nr. 50200302

CONTENTS

2 May 2006 / WHISPER 3,5 / EN

This manual applies to the Mastervolt Whisper 3,5 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 Nameplate......................................................................................................................................... 5

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

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

2.1.1 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 3,5 ............................................................................................................................................ 8

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

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

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

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

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

2.4.1 Main components to identify..............................................................................................................9

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

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

2.5 Technical Information.......................................................................................................................................10

2.5.1 AC alternator................................................................................................................................... 10

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

2.5.3 Digital Diesel 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 indicator..................................................................................................................................11

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

2.5.11 Oil information................................................................................................................................. 11

2.5.12 Technical data................................................................................................................................. 12

2.5.13 Wiring codes and colours................................................................................................................13

2.5.14 Lay out control PCB.........................................................................................................................14

2.5.15 Electrical diagram 230 V AC / 50 Hz ............................................................................................... 15

CONTENTS

EN / WHISPER 3,5 / May 2006 3

3 OPERATION.................................................................................................................................................................. 16

3.1 General ............................................................................................................................................................ 16

3.2 Operating Instructions ...................................................................................................................................... 16

3.2.1 Summarised operating instructions (daily use)................................................................................16

3.2.2 Extended operating instructions ...................................................................................................... 16

4 MAINTENANCE............................................................................................................................................................. 19

4.1 Alternator..........................................................................................................................................................19

4.2 Engine.............................................................................................................................................................. 19

4.2.1 Preliminary instructions ................................................................................................................... 19

4.2.2 Bleeding fuel lines ........................................................................................................................... 19

4.2.3 Valve clearance...............................................................................................................................19

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

4.2.5 Cleaning oil strainer......................................................................................................................... 20

4.3 Regular maintenance ....................................................................................................................................... 20

4.3.1 Maintenance schedule..................................................................................................................... 21

4.3.2 Putting out of service....................................................................................................................... 21

5 TROUBLE SHOOTING.................................................................................................................................................. 22

5.1 Alternator/ electrical faults ................................................................................................................................ 22

5.1.1 General............................................................................................................................................22

5.1.2 Trouble shooting table..................................................................................................................... 22

5.2 Engine faults..................................................................................................................................................... 23

5.2.1 General............................................................................................................................................23

5.2.2 Trouble shooting table..................................................................................................................... 23

5.2.3 Warnings......................................................................................................................................... 26

5.2.4 Service address............................................................................................................................... 26

5.3 Special procedures alternator........................................................................................................................... 26

5.3.1 Residual voltage check / excitation procedure ................................................................................ 26

5.3.2 Testing rotary rectifier diodes .......................................................................................................... 26

5.3.3 Winding resistant values.................................................................................................................. 27

5.3.4 Meggering ....................................................................................................................................... 27

5.4 Special procedures engine............................................................................................................................... 27

5.4.1 Setting the RPM .............................................................................................................................. 27

5.4.2 Tightening torques........................................................................................................................... 27

5.4.3 Measuring exhaust backpressure.................................................................................................... 27

5.4.4 Disassembling instructions.............................................................................................................. 28

6 SPARE PARTS LIST..................................................................................................................................................... 29

MAINTENANCE LOG ............................................................................................................................................................... 31

INTRODUCTION

4 May 2006 / WHISPER 3,5 / EN

1 INTRODUCTION

1.1 GENERAL

The Whisper 3,5 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 good understanding of ratings, features, design,
maintenance and operation procedures.
The information, specifications, illustrations and
statements contained within this publication are given with
our best intentions and are believed to be correct at the
time of going to press.
Our policy is one of continued development and we re­serve 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
consequences thereof.

WARNING

A warning symbol draws attention to special
warnings, instructions or procedures which, if
not strictly observed, may result in damage or
destruction of equipment, severe personal
injury or loss of life.

DANGER

This danger symbol refers to electric danger
and draws attention to special warnings,
instructions or procedures which, if not strictly
observed, may result in electrical shock which
will result in severe personal injury or loss of
life.

1.2 SERVICE AND MAINTENANCE

Regular service and maintenance should be carried out
according to the directions in this manual. For service and
maintenance one can appeal to the manufacturer or the
dealers.

1.3 GUARANTEE

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
generating sets are tested and inspected.

The 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. Some aspects of our warranty scheme are given
here in more detail: The guarantee period is two years,
limited to 1000 running hours. 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 t o
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 comp liant
installation. If in doubt ask!

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 c an 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.
Mastervolt cannot be held responsible for damage caused
by the unattended running generator.

INTRODUCTION

EN / WHISPER 3,5 / May 2006 5

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 authorized service
engineer is covered, but is limited to a reasonable number
of hours and reasonable rates in relation to the actual
repair work that has to be done.
Travel expenses and travel hours are not covered. Also
not covered is the labour required to take a generator out
of a 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.

Additional agreements could be part of the contract of
delivery.

If any problem arises which could be subject of guarantee,
procedures should be followed as described in the
guarantee certificate, unauthorised repairs could lead to
further damage and violate the guarantee conditions.

Should work take place, which is not in
accordance with the guidelines, instructions
and specifications contained in this user’s
manual and the supplementary installation
manual, then damage may occur and the
generating set may not fulfil its specifications.
In all these cases the guarantee may become
invalid

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 avoi ded
by additional measures. Mastervolt does not accept

liability for damage due to use of the ge nerator, 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

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 genera­ting set it is necessary that the operator knows the correct
specifications.

1.5.1 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:

2 POWER

The nameplate gives the nominal maximum continues
load in kVA (= kW) calculated with power factor one.
When calculating a load one should al ways take into
account the power factor or cos phi of this load. The

Model Whisper 3,5
Article number 050900500
Serial number

Max. power 3,6 KVA cos phi =0,8

3 KVA cos phi = 1
Voltage 230V ± 5%
Frequency 50 Hz
Current 13A
Phase Single phase
Dimensions

L x W x H

505x400x500mm

Weight 97 kg

Fig 1: Nameplate

INFORMATION

6 May 2006 / WHISPER 3,5 / EN

power should never exceed 3 kW. Power is rated at
an ambient temperature of 40°C and a seawater
temperature of 25ºC. 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
3000 rpm, 60 Hz correlates with 3600 rpm.

5 CURRENT shows the maximum current that is

acceptable at the specified frequency, voltage and
power factor.

6 WEIGHT shows the net dry weight (approximately) in

kg. This is without fuel, oil, 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 safet y of
pleasure craft, machinery, electric safety and electric
magnetic compatibility (EMC) and other relevant
directives.

Safety also relies on the installation, application and
circumstances. See also the remarks in this manual under
SAFETY

Before changing a factory setting you are advised to
consult the manufacturer. When the generating set you
have to identify is not new you have to take into account
the possibility that former users may have changed the
settings. Check the settings (voltage, frequency, rpm)
when there is any doubt.

2 INFORMATION

2.1 SAFETY

2.1.1 General

When correctly installed and used in normal
circumstances this generating set fulfils EC safety
regulations. This generating set could be part of an
installation or could be used in a way that additional
regulations of the EC or other authorities have to be taken
into account.

Circumstances could make it also necessary
to take additional measures. Be aware of wet
conditions and hazardous environments
caused by explosive gases etc

2.1.2 Electrical safety

The voltage of 230 Volt generated by this
generating set is dangerous and if instructions
and procedures are not strictly observed may
result in electrical shock which will result in
severe personal injury or loss of life.

• Check all wiring at least once a year. Defects,
such as loose connections, burned cables etc.
must be repaired immediately.

• Do not work on the electrical system if it is still
connected to a current source. Only allow
changes in your electrical system to be carried
out by qualified electricians.

• Connection and protection must be done in
accordance with local standards.

• Using the auto-start/stop (interval) mode the
generator can start unexpectedly. When working
on the electrical system, the 3 Amp fuse must be
removed from the control panel and the battery
plus cable must be removed from the battery.

Warning signs indicate parts which could be
live.

2.1.3 Earth insulation failures

According to local regulations and depending on the
application it could be necessary to take measures for
protection against earth insulation failures.
In the standard delivery “neutral” and “ground” are not
connected. To make a connection between “neutral” and
“ground” could be necessary as part of a specific
insulation failure protection system.

INFORMATION

EN / WHISPER 3,5 / May 2006 7

Small pleasure craft in Europe is submitted to The
Recreational Craft Directive 94/25/EC. The guidelines of
this directive refer to (ISO 13297).
When the installation complies with this standard the
“neutral” and “ground” should be connected on the
generating set. (Refer to the electrical diagram, page 15)

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.
Be aware that insulation protection systems can be
different for different applications and even within the shi p
there could be different standards for different spaces. We
did refer to the Recreational Craft Directive that applies to
pleasure craft up to 24 m of length. Sometimes one has to
comply with other standards such as the rules of
certification societies like Lloyds Register of Shipping or
Veritas, regulations for the protection of personal, building
legislation, etc. It is of the greatest importance to have
expert advice on this issue.

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 contain carbon

monoxide and are extremely dangerous.
Carbon monoxide (CO) is an invisible odourless gas.
Inhalation produces headache, nausea or death.
Installation includes measures for proper ventilation, safe
electric connections, safe installation of the starting
battery, proper fitting of the cooling system and fuel pipes
etc. Refer to the installation manual.

2.1.5 Operation

The Whisper 3,5 generating set does not have any
external moving parts like fans and V-belts and therefore
is very safe.

Nevertheless take note of the signs on the
generating set which show symbols in a
triangle indicating danger.

• The generating set should be operated by
authorised personnel only.

• Be aware of hot parts and especi ally parts of the
exhaust system.

• If the generating set is unsafe, fit danger notices
and disconnect the battery negative (-) lead so
that it cannot be started until the condition is
corrected.

• Do not attempt to operate the generating set with
a known unsafe condition. Disconnect the battery
negative (-) lead prior to attempting any repairs or
cleaning inside the enclosure.

• Always consult the manual before carrying out
maintenance.

• Do not ch ange the settings without consultin g the
manufacturer. Keep a record of setting changes
in this manual.

2.1.6 Fire and explosion

Fuels can be flammable. Proper handling
limits the risk of fire and explosion.

• Avoid refilling the fuel tank while the engine is
running. When oil or fuel is leaking do not use the
generating set.

• Do not run the engine close to explosives or
gasses.

• Hydrogen gas generated by charging batteries is
explosive. Ensure for proper ventilation. Do not
smoke or allow sparks, flames, or other sources
of ignition around batteries.

• Keep a fire extinguisher on hand.

• Poor electrical connections or using wiring which

is not suited for the rated currents can cause
overheating and possibly fire.

2.1.7 Chemicals

• Fuels, oils, coolants, and battery electrolyte can
be hazardous to personnel if not treated properly.
Do not swallow or have skin contact with these
liquids. Do not wear clothing that has been
contaminated by fuel or lubricating oil.

• Gaskets may be manufactured from asbestos.
Particles of this material should not be inhaled as
this may result in fatal diseases.

INFORMATION

8 May 2006 / WHISPER 3,5 / EN

• On no account allow any unprotected skin to
come into contact with the injector spray as the
fuel may enter the blood stream with fatal results.

• Engines may be fitted with seals or O-rings
manufactured from "viton" or similar material.
When exposed to abnormal high temperatures in
excess of 400°C an extremely corrosive acid is
produced which cannot be removed from the
skin. If signs of decomposition are evident, or if in
doubt, always wear disposable heavy duty
gloves.

2.2 TRANSPORT, LIFTING AND STORAGE

When lifting the generating set avoid any risk
of personal injuries, do not stand un-der the
generating set..

• Use soft slings to avoid damage

• Included in the delivery is a lifting eye, onl y 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 shoul d be
put through an engine preservation procedure.
(Refer to the maintenance chapter)

• The alternator windings tend to condense. To
minimise condensation, store the generating set
in a dry and warm storage area.

• After removing the generating set from long term
storage perform an insulation check. (Refer to the
alternator maintenance paragraph for
procedures)

• While th e battery is stored it should be recharged
every 12 weeks.

2.3 THE WHISPER 3,5

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 ar e guided
through the capsule’s left side. The set is not self
contained and is only operable after proper installation
using additional accessories and installation materials.
Installation accessories are listed in the installation manua l
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:

50200302) an installation manual (number: 50200311) and
a users manual for DCC (number: 50200261).
Not included in the standard delivery but available as
options are:

• Parts manual; number: 50200180

• Workshop manual; number: 50200170

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

• Fuel filter

• Fuel lift pump

• Lifting eye

• Special hose connector for measuring exhaust

backpressure (Refer to paragraph 5.4.3).

INFORMATION

EN / WHISPER 3,5 / May 2006 9

2.4 COMPONENTS

2.4.1 Main components to identify

1 Air inlet;
2 Starter motor;
3 Battery connection (positive);
4 Battery connection (negative);
5 AC 230 V wiring;
6 AC 230 V 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 Glow plug;
15 Injector;
16 Valve cover;
17 Decompression handle;
18 Oil filler cap;
19 Solenoid fuel valve;
20 Electric fuel lift pump;
21 Cooling water pump;
22 Oil pressure pump;
23 Fuel pressure pump
24 Oil pressure switch;
25 Oil sump pump;
26 Exhaust connection;
27 Fuel return;
28 Oil filler cap/ oil level indicator;
29 Control panel;
30 Capacitor;
31 Fuse 1;
32 Fuse 2;
33 Remote control cable;
34 Stop solenoid;
35 Oil strainer cover;
36 Start button;
37 Digital Diesel Control unit;
38 RPM set screw;
39 Oil temp switch;
40 Plug screw;
41 Heat exchanger.

Fig. 2: Overview Whisper 3,5.

18

19
27

25

40
23

38

37
30

29
31
32

36

34
24

28

1
39

14

2

41

20

7

26
3

9
4

10
11

6

1
17

15
16

12
13

3
4

21
22

35
33

20
5

8

INFORMATION

10 May 2006 / WHISPER 3,5 / EN

2.4.2 Generator control panel

Fig. 3: Control panel.
1 Fuse 3A;
2 Fuse 3A;
3 Start/stop button.

Fig... 4: Digital Diesel Control unit

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 alternator is directly coupled, one
bearing, brushless, rotating field design, t wo poles (3000
RPM) and self regulating.
Residual magnetism causes a small voltage over the
stator windings and allows a current to flow in the
windings, which is magnified because of the feed back
effect between rotor and stator. The field windings in th e
rotor are short-circuited over a diode to rectify the current.
A capacitor over an additional winding in the stator which
is at an angle with the power-winding keeps the voltage
stable within 5 % at the specified rpm and provides voltage
fall off with speed, preventing over-excitation at low engine
speeds and softening the effect of load switching to relieve
the burden on the engine.
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 3,5 generating set is based on the Kubota
OC60 1 cylinder diesel engine. The engine is indirectly
injected. The engine is oil cooled and the oil 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 adapte d for the Mastervolt
application and is very different from the standard engine
supplied for industrial applications!

2.5.3 Digital Diesel Control system

The standard electrical engine control system is 12 Volt
negative earth, non earth return (ungrounded) is available
as 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.

1

2

3

3A 3A

Fig. 5: Digital Diesel remote control panel.

1 2 6 5

3 4 7

INFORMATION

EN / WHISPER 3,5 / May 2006 11

2.5.4 Battery charger

There is an extra winding in the alternator generating 6
Amp 12 V. This current is rectified on the control PCB to
charge the battery. Both the current and the voltage are
regulated.

2.5.5 Alarms and shut down

In the event of malfunctioning this will be indicated by the
failure light and details 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 occur.
A contact is cut in the event of an alarm. This means that
the generating set will not work when the alarm switches
are broken or there is a loose wire. The system therefore
is intrinsically safe. The panel will display details about the
alarm.

2.5.6 Control

The generating set can be operated by push buttons on
the panel on the alternator or by the remote control. By
pushing the start button the control system is activated
and will start the engine automatically. Pushing the ST OP
button will stop the engine and the electrical system will be
deactivated. Stopping the engine is executed by the ‘pull’
solenoid, at the same time the fuel valve solenoid 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 cable can be
connected if the standard length does not suit the required
distance. Numerous remote control units can be put in
parallel by using the connectors on the back of the units.
(Refer to installation instructions)

2.5.8 Hour counter

The remote control offers several timer functions that
helps to schedule maintenance.

2.5.9 Load indicator

On the remote control the load will be indicated on the
display and by the LED-bar. The load is measur ed by a
current transformer on the alternator.

2.5.10 Fuel specification

The engine must only be used with diesel fuel oil which
conforms to the standards for use in modern diesel
engines. Fuel free from water and contaminants is of the
utmost importance.

2.5.11 Oil information

1 Specification:

The oil must be suitable for oil changes as specified in
the maintenance chapter. The Kubota 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 these
recommendations.
Using the wrong specification will cause high
oil consumption.

2 Oil viscosity:

We recommend a multigrade oil 15W40.

3 Oil capacity:

Excluding the oil cooler the content of the crankcas e
is 1,3 l. including the oil cooler it is 1,5 l.
Do not overfill with lubricating oil as this m ay have a
detrimental effect on engine performance.

4 Oil pressure

• Minimum at idle 49 Kpa (0,5 kgf/cm2 - 7psi).

• Normal at 3000 rpm between 147 and 4 90 Kpa

(1,5 up to 5 kgf/cm2 - 21 up to 71 psi).

• Minimum at 3000 rpm 98 Kpa (1,0 kgf/cm 2 - 14
psi).

INFORMATION

12 May 2006 / WHISPER 3,5 / EN

2.5.12 Technical data

GENERAL

Model WHISPER 3,5
RPM 3000
Alternator water cooled, synchronous
Engine Kubota diesel, model OC60 (Japan)
Number of cylinders 1
Displacement 276 cm3
Bore X stroke 72x68 mm
Combustion air consumption 0,38 m3/min.. at nominal RPM
Continuous power engine 3 kW nett.
Cooling system Indirect cooling by raw water.
Cooling water pump pto driven Mastervolt self priming impeller pump, type K
Fuel lift pump engine electric pump (12 V DC), additional pump available upon request
Starting battery (optional) 55-90 Ah
Fuel consumption 0.7-1.4 litre/hour, load dependent
Control Digital Diesel Control including automatic start/stop

ELECTRICAL SPECIFICATIONS

Output voltage 230V 50 Hz alternating current (AC) single phase
Output rating 3,6 KVA cos phi = 0,8; 3 KVA = 3 kW cos phi = 1
Voltage tolerance ± 5%
Frequency tolerance ± 5%
Alternator brushless, two pole, synchronous

MECHANICAL SPECIFICATIONS

Supply includes generating set, built into tugged GRP sound shield with steel bas e frame, m ounte d

on rubber anti vibration mounts
Dimensions hxwxd 500x505x405 mm
Colour top white, bottom green
Weight 97 kg including sound shield
Max. installation angle 25 degrees
Standard supplies Digital Diesel Control, remote panel (15 m cable)
Optional mobile (vehicle) version, non earth return, spare part kits

INFORMATION

EN / WHISPER 3,5 / May 2006 13

2.5.13 Wiring codes and colours

number colour cable code no

cross section
battery > starter motor red 16 mm2
starter motor > DCC 1 red 6 mm2
starter motor > LCP 13 red 2,5 mm2
battery > ground black 16 mm2
ground > LCP ground (GND) 2 black 2,5 mm2
DDC > glow plug 3 brown 4 mm2
DDC > starter solenoid 4 yellow 2,5 mm2
LCP > fuel lift pump + 5 brown 1,5 mm2
LCP > fuel lift pump – 15 black 1,5 mm2
DDC > LCD 5 grey 1,5 mm2
DDC > oil pressure switch 6 purple 1 mm2
LCP > oil pressure switch 6 purple/black 1 mm2
DDC > oil temperature switch 7 blue 1 mm2
LCP > oil temperature switch 7 blue/black 1 mm2
DDC > exhaust temperature switch 8 blue/green 1 mm2
LCP > exhaust temperature switch 8 blue/rose 1 mm2
DDC > fuel valve solenoid 9 green 1,5 mm2
DDC > stop solenoid 20 pink 2,5 mm2
DDC > current measuring transformer 11 black 1 mm2
DDC > current measuring transformer 11 red 1 mm2
DDC > LCP 19 orange 1,5 mm2
DDC > LCP 12 black 1,5 mm2
DDC > LCP 14 red 1,5 mm2
DDC > LCP 16 red/green 1,5 mm2
DDC > generator AC output 33 brown 1 mm2
DDC > generator AC output 33 blue 1 mm2
LCP > battery charger winding generator 10 red 1 mm2
LCP > battery charger winding generator 10 red 1 mm2

DDC=Digital Diesel Control Unit
LCP=Local Control Panel

INFORMATION

14 May 2006 / WHISPER 3,5 / EN

2.5.14 Lay out control PCB

Fig 7: Lay out control PCB

INFORMATION

EN / WHISPER 3,5 / May 2006 15

2.5.15 Electrical diagram 230 V AC / 50 Hz

Fig 8: Electrical diagram 230V

EARTH AND NEUTRAL CONNECTED

OPERATION

16 May 2006 / WHISPER 3,5 / EN

3 OPERATION

3.1 GENERAL

The generating set is operational after full installation and
filling up with: fuel, engine lubricating oil and cooling liquid,
filling the starter battery with acid, connecting the battery
to earth and connecting the digital remote control panel.

1 Filling cap
2 Minimum oil level
3 Maximum oil level
Fig. 9:

3.2 OPERATING INSTRUCTIONS

3.2.1 Summarised operating instructions (daily

use)

Routine "pre-start" checks:
1 Check oil level (refer to fig. 9).
2 Engine cooling system (all valves open).
3 Power source selector switch (off/shore

power/generator power). Switch to power source
switch "OFF", or switch off all consumers in the usual
way. If a MASTERSWITCH is installed, this operates

automatically.
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/generator power). Switch to power source
generator. If a MASTERSWITCH is installed, this
operates automatically.

5 Before loading the generating set up to maximum,

have it run warm. Continuous load should be
restricted 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 (i.e.
30% of 3 kW is approx. 1000W) and let it run for

approx. 5 minutes.
2 Press the STOP button.
3 Close the inlet sea water cock.
4 Switch to an other 230V 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 perio d
of rest:
1 If there is any damage caused by transport or

installation.
2 Check if installation conforms to the installation

instructions.
3 Ensure the generating set is free to turn without

obstruction.
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 the event 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 in the,

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

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

OPERATION

EN / WHISPER 3,5 / May 2006 17

3 Check the water strainer.
4 Check for leaks.
5 Regular ly 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
devices.

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 Whisper 3,5 can even be started with an almost
discharged battery using the cylinder compression release
handle. The engine can then be rotated easily ("turned
over") as the valves are opened i.e. in the decompression
position.
You can also use the decompression handle to readjust
the valve clearance and to fill the cooling system with anti
freeze for conservation in winter time.

A restart protection prevents starting the engine when it is
already running, which could cause damage.

In the event of starting problems (numerous
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 t o
the exhaust outlet, because 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
damaging the impeller.
Water in the cylinder will cause serious damage to the
engine. For instance; a bent piston rod or a cracked
cylinder head. In fact water in the cylinder 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.

Fig. 10: Decompression handle

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 throug h 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/generator power). Switch to power source

generator. If a MASTERSWITCH is installed, this

operates automatically.

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 run 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!

OPERATION

18 May 2006 / WHISPER 3,5 / EN

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 80% or the rated generating set’s maximum load.
Please note this when switching on your electrical devices!
Nevertheless, the Whisper 3,5 is designed so as not to
overheat, even under extreme conditions.

Do not run the generator for very long periods at no load
or at very low load. When this is necessary do load the
generator at least one hour in 10 hours for minimum 70%.
Long term running at too low load will cause the exhaust to
be choked by carbon.

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:

1 Avoid stopping of the gen erator abruptly after a long

period of operation at high load! Doing so, you av oid
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 influe nt
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

electric motors, compressors (in refrigerators or air

conditioners etc.).

2 Press the STOP button.

3 Close the inlet sea water cock.

4 Switch to an other 230V 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
button, otherwise it will drain the start battery

MAINTENANCE

EN / WHISPER 3,5 / May 2006 19

4 MAINTENANCE

4.1 ALTERNATOR

The alternator does not require any maintenance. Periodic
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
measurement 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 generator 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 carried out when the en­closure is open. For repairs we recommend to take out the
generating set to a workshop. The enclosure can be
completely removed by taking out the bolts form the
aluminium bars below the bottom of the capsule.
When oil and dirt have gathered in the enclosure
measures have to be taken to avoid spilling oil and
polluting the environment.

The first service on the engine should be carried out after
25 hours of its life. This also applies after a major over­haul. In the first 25 hours the engine should receive
special attention:
Long periods of light or no load running in the first 25
hours may lead to cylinder glazing and high oil
consumption.

For the same reason it is of the greatest
importance to use the right oil specification

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. Push the start button activating the electric
system and activating the fuel pump. When more time is

needed to bleed, push “start” and hold on the local control
panel (so not on the remote panel). Hold as long as
necessary to bleed the system.

Fig. 11: Self bleeding fuel lines

4.2.3 Valve clearance

Tightening torques, refer to § 5.4.2.
When the engine is in cold condition both valves shoul d
have a clearance between 0.14 and 0.18 mm. The
adjustment has to be done at T.D.C. of the compression
stroke. Using a pocket light one can check the position of
the flywheel (refer to picture 12). By using the
decompression handle one can crank the engine easily
with a screwdriver to put the marks in line. Confirm that the
valves do not move up or down when the crankshaft is
turned about 20 degrees in normal and reverse direction of
rotation. If the rocker arms move the piston is on the
T.D.C. of the intake or exhaust stroke. In such a case turn
the crankshaft 360° in the direction of engine rotation
again. The piston is now at T.D.C. of the compression
stroke. After readjustment one should crank the engine for
20 rotations and check the valves again.

Fig. 12: Valve clearance

MAINTENANCE

20 May 2006 / WHISPER 3,5 / EN

4.2.4 Replacing fuel filter

Filter change depends on contamination of the fuel, but
should be done however, at least every 1000 running
hours. Before changing the filter, clamp off the supply line.
Remove the hoses from filter and attach them on the new
filter again. The arrow on the filter housing indicates the
direction of the flow. A clogged filter results in a lack of
output of the generating set.

4.2.5 Cleaning oil strainer

The oil strainer is behind a plug on the bottom of the
engine. In the strainer is a magnet to catch the metal parts
which are in the lubricating oil. Once per 1000 hours or
when the oil is contaminated one can clean the strainer by
washing it with petrol or a solvent. A green rubber plu g in
the capsule gives access to the strainer. Before taking out
the plug one should sump the oil. Use tissues to avoid
spilling oil in the capsule.

4.3 REGULAR MAINTENANCE

CHECK DAILY:

• Oil level (see fig. 13) Take care the oil level is
never below the mark.

• Hoses for loose connections or deterioration.

• Water inlet filter.

1 Filling cap
2 Minimum oil level
3 Maximum oil level
Fig. 13:

AFTER FIRST 50 HOURS:

• Change oil.
Have the engine run until it is on temperature an d
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
engine 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.

• Check the valve clearance.

• 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
investigating the cause as this may result in an
expensive breakdown.

• Check siphon breaker valve or air vent on a
regular basis. When the air vent it not working
properly the engine can fill up with water by
siphoning. Water in the combustion chamber
causes serious damage to the engine.

EVERY 150 HOURS:

• Change oil.

• Check the battery acid level.

• Check battery terminals for corrosion

• Check impeller raw water pump (durability

depends on the purity of the sea water. In sandy
water and warm water wear 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.
Remove 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 i.e. anti clockwise looking at
the impeller.

EVERY 300 HOURS:

• Replace the impeller of the raw water pump.

• Check valve clearance.

MAINTENANCE

EN / WHISPER 3,5 / May 2006 21

EVERY 1000 HOURS:

• Replace the fuel filter
Replacement depends on the condition of the
fuel. We recommend replacement every 1000
hours. Isolate the fuel supply and change the
element.

• Clean the oil strainer.

EVERY 2000 HOURS:

• Check lubricating oil pressure

• Clea n 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 oil is indirectly cooled by raw water
via an oil cooler/ 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 resistant materials such as 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 clea n 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

Check oil level daily
Check water strainer daily
Change oil 150 hours
Check air vent 150 hours

Check impeller water pump 150 hours
Check valve clearance 300 hours
Replace impeller water pump 300 hours
Replace fuel filter 300 hours
Clean the oil strainer 1000 hours
Check injector and injection pressure 2000 hours
Check inlet air filter 2000 hours

4.3.2 Putting out of service

When not using the generating set for a longer period it is
recommended to execute an engine preservation
procedure.

1 Clean the engine.

2 Loosen the fuel suction pipe and fuel retur n 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 loosen the inlet of the ra w water

pump. Drain the water from the water lock. Lift the
valves by the decompression handle to avoid the
engine from starting and crank the engine having the
raw water inlet sucking anti freeze from a can until the
pump, heat exchanger and manifold are full.

5 Disconnect the batter y and store it in a place free of

frost and dry and charge it regularly.

6 Close inlet- and outlet openings with tape.

7 Protect the generating set against the influences of

bad weather conditions.

This method of preservation will be sufficient for 6 months.
Repeat steps 2, 3, and 4, every 6 months. Change oil
before using the engine again.

TROUBLE SHOOTING

22 May 2006 / WHISPER 3,5 / EN

5 TROUBLE SHOOTING

5.1 ALTERNATOR/ ELECTRICAL FAULTS

Beware of parts which are live!

Remove 3 Amp. Fuse in the control panel
while working on the generator to prevent the
engine from starting

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 directly 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 3000 (50 Hz)
RPM according to its settings and does as well under load.
A RPM drop of 5% at full load is acceptable. There-fore a
no load setting should be at 3150 RPM = 52.5 Hz or 3750
RPM = 62.5 Hz. Under no circumstances should the RPM
under full load be below 2940 RPM = 49 Hz or 3540 = 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

• Circuit breaker "off" or faulty fuse

Check switches and fuses and measure
directly 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 capacitor or in the windings.

No output (Voltage) at all

• Rotor diodes broken.

Check the diodes in the rotor (refer to special
procedures) The Whisper 3,5 has two diodes
in the rotor. It happens very rarely that both
are broken. When only one diode is broken the
voltage will be low but will not varnish
completely.

• No load at all or very low load.

Switch on a load and check voltage.

• Engine is not reaching the rated RPM.

Refer to special procedures to readjust RPM.

• Defective capacitor.

Check capacitor and replace if necessary
(refer to special procedures).

Generator output voltage too
low when no load is on it (less
than 210V).

• Defective diode (one of the two)

Check the diodes in the rotor and replace
(refer to special procedures).

• Generator is overloaded.

Switch off a load; (part off) consumers.

• Engine is not reaching the rated RPM.

Refer to engine RPM problems

Generator output voltage too
low under load (less than 210V).
In no load condition it is ok

• Defective capacitor

Check capacitor and replace if necessary
(refer to special procedures).

• Engine is running too fast (RPM too
high).

Check engine speed and adjust (refer to
special (more than 245V).procedures).

• Over-energising due to defective
capacitors

Check capacitor specification and replace
capacitors if necessary.

Generator voltage too high,
(more than 245V)

• Presence of a strong capacitive load
(leading power factor)

Compensate for this capacity and seek for
experts advice.

TROUBLE SHOOTING

EN / WHISPER 3,5 / May 2006 23

PROBLEM CAUSE SOLUTION

• Disturbances on the electrical system/
user side.

Check if electrical load is fluctuating

Generator voltage fluctuates.

• Engine runs irregularly.

When engine runs irregularly refer to section:
"Engine runs irregularly".

Generator is not able to start an
electric motor

If the generator is unable to supply
enough power to start an electric
motor (230V), this is usually
because this motor draws too much
current during starting

Check the electric motor’s current draw
required for starting. This should not exceed
70% of the rated generator output current. This
could be 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 ENGINE FAULTS

Remove 3 Amp. fuse in the control panel
while working on the generator to prevent the
engine from starting.

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. When
there is no obvious cause one can adjust the RPM (refer
to special procedures). The Digital Diesel Control s ystem
will help to indicate failures and display causes.

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 cylinder 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

5.2.2 Trouble shooting table

PROBLEM CAUSE SOLUTION

• Almost certainly this is an electrical
problem or the engine is locked by
water in the cylinder or there is other
severe damage. Display will indicate
low battery voltage.

Check on water in the cylinder and further
damage by cranking while lifting the valves
with the decompression handle. When there is
water in the cylinder, then deactivate the
control system, disconnect the battery, remove
the glow plug. Crank the engine to remove the
water through the opening of the glow plug.
Check oil on the presence of water and
change oil. Find out how the water entered the
cylinder (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.

Diesel engine fails to crank, the
starter makes clicking noises, or
the engine cranks very slowly

• Starter battery switched "OFF".

Check position of the battery switch and switch
"ON".

TROUBLE SHOOTING

24 May 2006 / WHISPER 3,5 / EN

PROBLEM CAUSE SOLUTION

• Starter battery voltage insufficient
(battery too weak).

Check battery voltage. Recharge the battery.
Inspect battery terminals and cables for a good
electrical connection (inspect against
corrosion, tattered wires, etc.)
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.

• Out of fuel or faulty fuel, water in the
fuel.

Fill up with fuel or replace with better quality.

• Fuel inlet solenoid valve is not opening.

Check wire connections and circuitry to
solenoid. (Refer to DC wiring diagram)

• Fuel lift pump is not working.

• Fuel filter is blocked.

• Air in fuel lines.

Check fuel filter and fuel lift pump: clean or
replace if necessary.
Bleed air from fuel system (refer to
maintenance section).

• Low compression because of dirty
valves.

Clean valves. Take off the injection bent and
inspect the outlet port. When little rust in the
port clean the valve by taking off the valve
spring and rotate until rust is removed. When
the outlet port is strongly affected by rust, the
exhaust system is not properly installed (refer
to paragraph 5.4.3).
Contact Mastervolt service department for
advice.

• Wrong valve clearance.

Adjust valve clearance,

Starter is turning engine
smoothly, but engine fails to
start

• Blocked injector.

Have the injector tested and cleaned if
necessary.

• Unsuitable contaminate d fuel

• Lack of fuel.

Fill up with fuel or replace by better quality.

• 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.

• Lack of air.

Check the air intake

• Choked exhaust system, exhaust
chocked rubber exhaust hose kinked.

Check the exhaust hose

• 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.

Engine runs irregularly.

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

• 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.

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

Check exhaust system.

• Generator overloaded by over-
energising.

Reduce the electrical load (switch off some
consumers).

• Generator over energised.

Check that the proper capacitor type is
installed and that it is connected correctly.

• Defective generator (windings,
bearings or other)

Generator must be sent to manufacturer for
repair of damaged bearing or winding.

Engine speed drops

• Damaged engine

Repair by Mastervolt service

TROUBLE SHOOTING

EN / WHISPER 3,5 / May 2006 25

PROBLEM CAUSE SOLUTION

Engine does not stop on
command

• • Loss of control

Faulty Digital Diesel Control unit. Stop the
engine manually by the stop handle.
Check wire connections to stop solenoid.
Check solenoid valve function. Replace if
necessary.

Engine exhaust smokes

• Faint blue smoke - generally the result
of light load

Increase load.

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

Check the oil level.
Check the compression.

• Black smoke –incomplete combustion
caused by: Overload, choked air filter,
inlet temperature too high, unsuitable
fuel or water in fuel.

Check the fuel .
Check for overload.

Engine starts, but stops after 10
up to 30 seconds

• Protection system stops the engine;
this can be caused by oil pressure
failure, lack of cooling water (exhaust
temperature alarm). Overload, loose
wire or faulty alarm switch. Digital
Diesel Control will help to indicate
failure.

Refer to paragraph 2.5.5. and 3.2.2 for
information on the alarm system. Bypassing
the switches can help to confirm the failure.

• 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
tripped).

Check oil level.
Check engine’s oil pressure and have it
repaired by Mastervolt.

• Excessive heat in cooling system
(thermo-switch tripped).

• 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.

Check cooling water system flow: water pump,
inlet water filter, coolant flow.

• Loss of compression by wear out or
damage.

Repair by Mastervolt service.

Engine stops by itself

• Overload or short circuit.

Switch off the consumers and test for short
circuit.

• Generator is being overloaded. Digital
Diesel Control will indicate “overload”.

Check electrical load and switch off some
consumers

• Insufficient intake air.

• Choked air filter.

Check intake air paths and filter, clean and
replace if necessary.

• Fuel injector faulty.

Replace injector.

• Valve clearance incorrect.

Readjust valve clearance

• Poor fuel quality.

Use better quality diesel.

• Poor quality lubricating oil.

Use better quality oil.

Sooty, black exhaust.

• Continuous running with very low load.

Increase load and have the engine run for a
few hours

• 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 fuel filter.

Replace the fuel filter.

Loss of power

• Choked air filter.

Check air inlet openings; clean air filter.

TROUBLE SHOOTING

26 May 2006 / WHISPER 3,5 / EN

PROBLEM CAUSE SOLUTION

• Exhaust blocked.

Check the exhaust system.

• Injector blocked.

Have the injector checked.

• Loss of compression, sticking.

Have the compression measured.

• damaged piston ring.

Clean or replace the rings.

• Wear out of cylinder.

Have the compression measured and have the
engine overhauled.

• Overload.

Take away the overload.

• Low oil level.

Fill up with oil.

• Water inlet system blocked.

Check the cooling system thoroughly.

• Broken impeller.

• Water strainer choked

• Heat exchanger choked.

Over-temperature

Engine stops very slowly

• • Engine should stop within 20 seconds

Stop solenoid is faulty an engine is stopped by
after pushing stopping button fuel shut off
valve

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 mal­function table, contact your Mastervolt Service Centre or
Mastervolt Amsterdam for an extended service list, tel: INT
[phone].

5.3 SPECIAL PROCEDURES ALTERNATOR

5.3.1 Residual voltage check / excitation
procedure

When residual magnetism disappears there is no residual
voltage. Residual magnetism can disappear after the
generating set being out of service for a long period or
suffered a short circuit. This can be solved by char ging the
capacitor ("flashing") independently with a small 9 Volt
battery. This can be done while the engine is stationary
and the wiring is connected.

If the generating 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
capacitor(s) should be renewed. When this does not help,
the rotating rectifier diodes should be tested and a winding
resistant test should be executed.

5.3.2 Testing rotary rectifier diodes

The diodes in the rotor can be checked with a multimeter.
When both diodes are faulty the alternator will not
generate any voltage. When only one diode is faulty the
alternator will generate about half the normal voltage. The
flexible lead connected to the diode should be
disconnected 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. The problem can also be in a faulty surge
suppressor which is a metal-oxide varistor connected
across the diodes, or the ESD capacitor. Replace the
diodes, the suppressors and the capacitors.

Fig. 14.

TROUBLE SHOOTING

EN / WHISPER 3,5 / May 2006 27

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 50Hz

• Resistance both main stator windings
in series

1.2 Ohm

• Resistance both rotor windings

2.1 Ohm

• Resistance battery charger windi ng

0.15 Ohm

• Resistance exciter stator winding

2.4 Ohm

5.3.4 Meggering

One can try to measure resistance between the housing
and the windings with a multimeter which should read
infinity. When readings are 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
3000 (50 Hz) RPM. A RPM drop of 5% at full load is
acceptable. Therefore a no load setting should be at ±
3150 RPM = 52.5 Hz. Under no circumstances should the

RPM be under full load below 2940 RPM = 49 Hz. When
no cause can be found for a wrong speed, the s etting can
be adjusted: It is very important to identify the correct
setting assembly (refer to fig. 16).The screw is to be
locked in position with the lock-nut.

5.4.2 Tightening torques

Valve clearance, refer to Maintenance, §4.2.3.
Cylinder head screws M10x1,5:
51,9 to 56,8 Nm; 5,3 to 5,8 kgf-m.
Rocker arm bracket mounting: M8 x 1,25:
23,5 to 27,4 Nm; 2,4 to 2,8 kgf-m.

5.4.3 Measuring exhaust backpressure

The exhaust system must be of adequate size -1 5/8”/ 40
mm no more-no less -and maximal length (refer to
installation manual). This is true for all generators, but
specially for the Whisper 3,5, because this small engine
has a small gas flow that easily can be blocked by a wate r
trap in the exhaust system. 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 alo ng 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 that is characteristic for a one
cylinder engine. The water column should be no more than
24 inches (60 cm.) of water (0,87 PSI - 0,06 bar)

1 Varistor (420V);
2 EMC capacitors (4,7nF - 630V);
3 Diodes (25A - 1200V). Fig15

Fig16: Setting assembly

TROUBLE SHOOTING

28 May 2006 / WHISPER 3,5 / EN

5.4.4 Disassembling instructions

It could be necessary for repair or checks to disassemble
the generating set. One can take off the white cover easily
for regular maintenance and inspection. For further repair
or inspection one can take off the upper green part as well.
Following instructions will help:

1 When the generating set has to be taken out of its

enclosure we strongly advise not to do this in a
narrow space on a boat, but to take out the complete
set and take it to a workshop.

2 To take out the generator all connections have to be

taken off. The outgoing hose on the oil cooler is most
difficult to get to, but can be reached from above by
taking off the cover which is on the cylinder head of
the engine. By taking out 4 screws from the aluminium
bars the generating set will come loose from the
capsule.

3 The easiest way to get the generator out of its capsule

is by lifting the set using the lifting eye and removing
the capsule downwards.

4 The cooler elements are welded to the alternator

housing with silver and cannot be disassembled.
How-ever 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 oil cooler to be able to take off the
aluminium housing. All cables and wiring have to be
loosened first.

6 The rotor can be taken off by removing the bolt 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 6-mm rod of 165-mm length and a
M10 bolt.

7 Reassembling the generating set one should take

care of alignment, cleaning the surfaces between
engine and alternator and tighten the bolts crosswise
and gradually.

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

be cleaned and made free of oil and grease. Test the
generating set first outside its capsule and check very
carefully for leakages before putting it back in its
enclosure.

Fig 17: Measuring exhaust backpressure

0

4

SPARE PARTS LIST

EN / WHISPER 3,5 / May 2006 29

6 SPARE PARTS LIST

A parts manual in English is available as an option number: 50200180(* **).
A work shop manual in English is available as an option number: 50200170(***).

We recommend the following spares for service and maintenance.

• Kit A: parts for regular maintenance parts marked(*) article no 50201260

• Kit B: parts for maintenance + spare parts: all parts marked (*)+(**) article no 50201261

• Kit C: parts for "world travellers" all parts marked (*)+(**)+(***) article no 50201262

ARTICLE NO DESCRIPTION

50209030 Fuel filter (*)
50201031 Fuel lift pump (**)
50201051 Fuel valve solenoid (**)
50221609 Banjo eye fuel valve (**)
50201034 Copper washer connection bolt, M10 x 16 (**)
50201035 Copper washer, M12 x 18 (**)
50202048 Stop solenoid (***)
50201250 Raw water pump complete Mastervolt type K (***) (refer to fig. 17)
50209011 Impeller + gasket (3,4,5) (*)
50201012 Cover type K (**) (2)
50209018 Bolts cover (**) (1)
50201251 Pump repair kit A consisting of:

- Shaft (13)

- Bearings (2 pcs.) (10)

- O-ring (9)

- Seals (2 pcs.) (8)

- Clips (1 set) (11, 12)
50209010 Pump repair kit B (**)(same as repair kit A excluding the shaft)
50201220 Oil cooler complete with appendages (***)
50201225 Oil pipes and fittings (***)
50201222 Water hoses with clamps (***)
50201060 Capacitor xx micro-farad (**) xx = give value when ordering
50209132 Measuring coil (***)
50201290 Rotary diodes (2 pcs) (including varistors and capacitors (**)
50201085 Alternator bearing including O-ring (**)
50209100 Digital Diesel Control unit (black box) (***)
50209104 Local control panel on the engine (***)
50212154 Fuses 3 Amps (*)
50212170 Fuses 10 Amps (*)
50201066 Wiring loom complete (***)
50209102 Digital Diesel Remote Control panel (***)
50209133 Cable remote control 15 mtr, including connectors
50202034 Gasket valve cover (**)
50202030 Cylinder head gasket kit
50202036 Overhaul gasket kit + seal kit (***)
50202040 Glow plug (**)
50202050 Nozzle injector (**)
50202160 Fuel pump (high pressure) complete (***)
50209051 Silicone O-ring sound shield cover (**)

More extensive parts list on the internet: MASTERVOLT.COM (fast moving parts)

SPARE PARTS LIST

30 May 2006 / WHISPER 3,5 / EN

Fig. 18 Waterpump type K

MAINTENANCE LOG

EN / WHISPER 3,5 / May 2006 31

MAINTENANCE LOG

first service after 50 hours: hour counter: remarks

next service (every 150 hours) hour counter:

Snijdersbergweg 93, 1105 AN Amsterdam, The Netherlands

Tel : + 31-20-3422100 / F ax : + 31-20-6971006

www.mastervolt.com / [e-mail]