Mastervolt WHISPER 6 ULTRA User Manual

Download

Page 1

MASTERVOLT

Snijdersbergweg 93

1105 AN Amsterdam

The Netherlands

Tel.: +31-20-3422100

Fax: +31-20-6971006

www.mastervolt.com

USERS MANUAL FOR MOBILE APPLICATIONS

V1. July 2004

WHISPER 6 ULTRA

-1500 RPM-

Mobile diesel generating set 230V-50 Hz

Digital Diesel Control

Art.nr. 50200329

Page 2

2 July 2004 / WHISPER 6 ULTRA Mobile / EN

CONTENTS

This manual applies to the Mastervolt Whisper 6 ULTRA mobile 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

1.5 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

1.5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

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 6 ULTRA generating set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

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

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

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

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

2.4.1 Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

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 charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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 specification, oil viscosity, oil capacity,, oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

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

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

Page 3

EN / WHISPER 6 ULTRA Mobile / July 2004 3

CONTENTS

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

2.5.15 Lay out control Wiring 12V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

2.5.16 Electrical diagram 230V 50Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

2.5.17 Diagram fan control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

3.2 Operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

3.2.1 Summarised operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

3.2.2 Extended operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

4 MAINTENANCE AND CARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

4.1 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

4.2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

4.2.1 General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

4.2.2 Bleeding fuel lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

4.2.3 Valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

4.2.4 Replacing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

4.2.5 Replacing the oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

4.2.6 Readjusting V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

4.3 Regular maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

4.3.1 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

4.3.2 Putting out of service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

5 TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

5.1 Alternator malfucntions / AC trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

5.1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

5.1.2 Trouble shooting check list alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

5.2 Engine malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

5.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

5.2.2 Trouble shooting check list engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

5.2.3 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

5.2.4 Service address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

5.3 Special procedures alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

5.3.1 Residual voltage check / excitation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

5.3.2 Testing rotary diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

5.3.3 Windings resistance values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

5.3.4 Meggering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

5.4 Special procedures engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

5.4.1 Readjusting RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

5.4.2 Valve clearance / retightening cylinder head bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

5.4.3 Measuring exhaust by backpressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

5.4.4 Disassembly instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

6 SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Maintenance log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Page 4

4 July 2004 / WHISPER 6 ULTRA Mobile / EN

INTRODUCTION

1 INTRODUCTION

1.1 GENERAL

The Whisper 6 ULTRA Mobile 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 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.

Realise that people are not used to have

230V available on a vehicle. Put warning

signs on wall sockets and on junction

boxes. Instruct non-regular users of the

vehicle. Warn maintenance personal of

garages that do service on the vehicle.

1.2 SERVICE AND MAINTENANCE

Regular service and maintenance should be executed

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 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. 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 or a faulty installation.

Example 1. Faulty installation:

Overheating of the engine is the most common cause of

problems with mobile generating sets. These problems are

caused by poor circulation of the cooling liquid due to

incorrectrouting of the pipes to the radiators: bends will

capture air bubbles causing “air-locks” blocking the

circulation of the liquid. Other examples of installation

problems are hot air circulation into the radiators and the

radiator fans sucking exhaust gases into the radiators.

The generator and other parts should be protected against

the influences of the weather and splashing water (with dirt

and salt) below the vehicle. Refer to the installation manual.

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

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.

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

Page 5

EN / WHISPER 6 ULTRA Mobile / July 2004 5

INTRODUCTION

board a vehicle 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 vehicle or for reinstallation. There is no cover for

labour needed to get access to the generator, for

example to remove equipment or parts of the carroserie

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 water, 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 and are

not refunded.

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 SE-

RIAL 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 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.

810x525x615 mm

25 A

5,7 kW at cos phi = 1

50905020

Whisper 6 ULTRA

225 kg

230 V

50 Hz

SINGLE PHASE

PHASE

DIMENSIONS WxDxH

WEIGHT

ARTICLE NO

MODEL

SERIAL NUMBER

MAX. POWER

VOLTAGE

FREQUENCY

CURRENT

Fig. 1: Nameplate.

Page 6

6 July 2004 / WHISPER 6 ULTRA Mobile / EN

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 have 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 gases etc.

2.1.2 Electrical safety

The voltage of 230 Volt generated by this

generating set is dangerous and if instruc-

tions and procedures are not strictly obser-

ved may result in electrical shock which

will result in severe personal injury or loss

of life.

Remember that people are not used to

have 230V available on a vehicle. Put

warning signs on wall sockets and on

junction boxes. Instruct non-regular users

of the vehicle. Warn maintenance personal

of garages that do service on the vehicle.

• Check all wiring at least once a year. Defects,

such as loose connections, burned cables etc.

must be repaired immediately.

• Do not work on the electrical system if it is still

connected to a current source. Only allow chan-

ges in your electrical system to be carried out by

qualified electricians.

• 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.

• Connection and protection must be done in accor-

dance with local standards.

Warning signs indicate parts which could

be live.

2.1.3 Earth insulation failures

According to local regulations and depending on the ap-

INFORMATION

The power should never exceed the nominal Power

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

an ambient temperature of 40°C and a seawater tem-

perature of 25ºC. For higher temperatures the gene-

rating 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

1500 rpm.

5 CURRENT shows the maximum current that is ac-

ceptable at the specified frequency, voltage and po-

wer factor.

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 may have changed the

settings. Check the settings (voltage, frequency, rpm)

when any doubt.

Page 7

EN / WHISPER 6 ULTRA Mobile / July 2004 7

INFORMATION

plication it could be necessary to take measures for

protection against earth insulation failures.

In the standard delivery “neutral” and “ground” are not

connected. To make a connection between “neutral” and

“ground” could be necessary as part of a specific

insulation failure protection system.

In all situations the transfer switches

between shore, inverter and generator

should switch both neutral and L1. Of

course this is the case when using a

Mastervolt Masterswitch.

2.1.4 Installation

Whisper generating sets are not self contained and have

to be properly installed in enclosed areas. Installation

includes measures to be taken to outlet exhaust fumes

which contains carbon monoxide and are extremely

dangerous. Carbon monoxide (CO) is an invisible

odourless gas. Inhalation produces headache, nausea or

death. Installation includes measures for proper

ventilation, safe electric connections, safe installation of

the starting battery, proper fitting of the cooling system

and fuel pipes etc. Refer to the installation manual.

Do not use the generator set when the

vehicle is inside a building or in other

enclosed area’s.

Be aware when using the generator in still

conditions, as the exhaust fumes could

accumulate under, around or even in the

vehicle.

2.1.5 Operation

External moving parts like fans and V-belts are covered

by the canopy and therefore the Whisper 6 ULTRA is

very safe, when the canopy is closed

Nevertheless 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 carrying out

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

gases.

• 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.

Page 8

8 July 2004 / WHISPER 6 ULTRA Mobile / EN

INFORMATION

Particles of this material should not be inhaled as

this may result in fatal diseases.

• On no account allow any unprotected skin to

come into contact with the injector spray as the

fuel may enter the blood stream with fatal results.

• Engines may be fitted with seals or O-rings

manufactured from "viton" or similar material.

When exposed to abnormal high temperatures in

excess of 400ºC 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 6 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 16.

2.3.3 Documentation

Included in the delivery is this users manual (number:

50200129) an installation manual (number: 50200369)

and a users manual for DDC (number: 50200361).

Not included in the standard delivery but available as an

option are:

• Parts manual; number: 50200382

• Workshop manual; number: 50200171

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.

Page 9

EN / WHISPER 6 ULTRA Mobile / July 2004 9

INFORMATION

1617 36 22 38

32 31 29

5 33 25 1 28 21

3627181638

14 15

121234

Fig. 2: Overview Whisper 6 ULTRA.

2.4 COMPONENTS

2.4.1 Main components to identify

1 Air inlet;

2 Starter motor;

3 Battery connection ( negative);

4 Battery connection ( positive);

5 AC 230V wiring;

6 AC 230V output connection box;

7 Fuel filter;

8 Fuel pipe inlet;

9 Fuel pipe return;

10 Bypass hose air vent;

11 Cooling connections;

12 Exhaust manifold (water cooled);

13 Thermo-switch alternator;

14 Injector 3x;

15 Glowplug 3x;

16 Valve cover;

17 Circulation pump engine cooling;

18 Filling cap oil 2x;

19 Solenoid;

20 Electric fuel lift pump;

21 Water pump alternator cooling;

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 /

optional voltage regulator;

31 Fuse 2;

32 Fuse 1;

33 Remote control cable;

34 Cooled exhaust bent;

35 RPM adjustment screw;

36 Thermostat housing;

37 Alternator;

38 Filling cap coolant;

40 Drain plug coolant;

41 Stop lever;

42 Oil filter.

43 Digital Diesel Control Unit

Page 10

10 July 2004 / WHISPER 6 ULTRA Mobile / EN

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 (1500 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. The

alternator is watercooled and the cooling liquid is cooled

by a radiator.

2.5.2 Engine

The Whisper generating set is based on the Mitsubishi L3E

3 cylinder diesel engine. The engine is indirectly injected.

The engine is water cooled and the cooling liquid is cooled

by a radiator.The engine has been specially adapted for the

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.

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 the event of malfunctioning this will be indicated by the

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

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

1 2

4 3

Page 11

EN / WHISPER 6 ULTRA Mobile / July 2004 11

INFORMATION

failure light and detail will be shown on the display the

engine will be shut down. There are three functions

guarded: oil pressure, coolant temperature and alternator

temperature. Exhaust temperature too high indicates the

alternator cooling water to be blocked. All alarm switches

are closed when no malfunction occurs. A contact is cut

in the event of an alarm. This means that the generating

set will not work when the alarm switches are broken or

there is a loose wire. The system therefore is intrinsically

safe. The panel will display details about the alarm.

2.5.6 Control

The generating set can be operated by push buttons on

the panel on the alternator or by the remote control. By

pushing the START button the control system is activated

and will start the engine automatically. Pushing the

STOP button will stop the engine and the electrical

system will be deactivated. 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 neces-

sary an optional longer 8 wire twisted cable can be

connected if the standard length does not suit the requi-

red 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 to 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

1 Specification:

The oil must be suitable for oil changes as specified

in the maintenance chapter. The Mitsubishi engine

must be run on heavy duty lubricating oil meeting the

requirements of API class 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 10W40.

3 Oil capacity:

Excluding the oil filter the content of the crankcase is

3,6 l. Including the oil filter it is 4,1 l.

Do not overfill with lubricating oil as this may have a

detrimental effect on engine performance.

4 Oil pressure

• Minimum at idle 98 Kpa (1 kgf/cm2/14psi)(1 bar).

• Normal at 1500 rpm ±250 Kpa (2,5 kgf/cm2/ 35

psi)(2,5 bar).

2.5.12 Cooling liquid

The engine and alternator are cooled by cooling liquid.

The capacity of both systems depend on the capacity of

the radiator piping and other parts of the cooling system.

We recommend not using water but cooling liquid that is

marketed for the use in combustion engines. Cooling

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

Also it protects the engine block against corrosion.

Initially one can fill the engine via the filling cap on the

exhaust manifold. Fill up till the level is just below the

filling cap. Filling of the alternator cooling system and

additional filling of engine cooling system has to be done

via the expansion tanks. When the engine is on

temperature the liquid will expand and the redundant

liquid will be pressed into the expansion tank. This tank

has to be filled up to the mark. On the tank is an overflow

connection. This should be open hose can be connected

to drain the overflow to outside the vehicle. When cooling

liquid is not available clean fresh water could be used

with an additive of anti freeze. When using water with

anti freeze the right mixture has to be cal-culated

according to the information of the supplier of the anti

freeze. The cooling system is not pressurised. There

should be a special cap on the engine manifold without

valves leaving the connection to the expansion tank

open.

Page 12

12 July 2004 / WHISPER 6 ULTRA Mobile / EN

INFORMATION

2.5.13 Technical data

GENERAL

Model WHISPER 6 ULTRA RPM 1500 rpm Alternator water cooled, synchronous Engine Mitsubishi diesel, model L3E (Japan) Number of cylinders 3 Displacement 952 cm

Bore X stroke 76x70 mm Combustion air consumption 0.9 m3/min. Continuous power 50Hz 5,7 kW Cooling system by radiator Fuel lift pump engine electric pump (12 V DC), additional pump available upon request Starting battery (optional) 60-90 Ah12V Fuel consumption 1.5-2,5 litre/hour, load dependent Enaine control Digital Diesel Control

ELECTRICAL SPECIFICATIONS

Output voltage 230V 50 Hz alternating current (AC) single phase Output rating 50Hz (ULTRA) 5,7 kW at power factor cos phi = 1 Voltage tolerance ± 5% (optional voltage regulator 2%) Frequency tolerance ± 5% Optional electronic 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 810x525x615 mm Colour top white, bottom green Weight 225 kg including canopy Max. installation angle 25 degrees Standard supplies remote panel (+15 m cable), fuel filter, fuel lift pump, user and installation

manuals

Optional installation kits, non earth return, spare part kits

Page 13

EN / WHISPER 6 ULTRA Mobile / July 2004 13

INFORMATION

2.5.14 Wiring codes and colours

Cable code number colour cross section

STANDARD

battery > starter motor red 25 mm2

starter motor > DDC 1 red 6 mm2

starter motor > LCP 13 red 2,5 mm2

battery > ground black 25 mm2

ground > LCP ground (GND) 2 black 4 mm2

DDC > glow plugs 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 > water temperature switch 7 blue 1 mm2

LCP > water 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 solenoid (hold) 9 green 1,5 mm2

DDC > fuel solenoid (pull) 20 pink 1,5 mm2

DDC > fuel solenoid (com.) 17 black 1,5 mm2

B+ terminal alternator > starter motor 21 red 6 mm2

DDC > R terminal alternator 18 wit 1,5 mm2

DDC > L terminal alternator 19 orange 1,5 mm2

DDC > current measuring transformer 11 black 1 mm2

DDC > current measuring transformer 11 red 1 mm2

DDC > LCP 12 black 1,5 mm2

DDC > LCP 14 red 1,5 mm2

DDC > LCP 16 red/green 1,5 mm2

DDC > generator AC output 33 brown 1 mm2

DDC > generator AC output 33 blue 1 mm2

DDC=Digital Diesel Control Unit

LCP=Local Control Panel

Page 14

14 July 2004 / WHISPER 6 ULTRA Mobile / EN

INFORMATION

2.5.15a Lay out control wiring 230V AC Radiator fan

hold

ct-2

ct-1

ct-2

gnd

tem

str.

exh

oil

reg

alt.

fuel

heat start fuel fail

pull

AC-1

AC-2

LOCAL CONTROL PANEL

J28

3xPUMP OUTPUT

ALT

REGULATOR

J22

START/STOP

J8 J9

J10

J11

J12

J13

J14

J16

J15

J17

WCH/1

TAILOR MADE ENERGY

ALT-L

MASTERVOLT

3A 3A

10A

ALT

J24

J21

J23

J19

J18

SOLENOID

FUEL

WHITE (HOLD)

BLUE (COM.)

RED (PULL)

BATTERY

RED 25

12VDC

RED 2,5 (1)

BLACK 25

GROUND TO

BLACK 4 (2)J17

WATER TEMP.

SWITCH

GENERATOR TEMP.

SWITCH

OIL PRESS.

SWITCH

MOTOR

STARTER

CURRENT MESURING

TRANSFORMER

BLUE 1 (7)

BLUE/GREEN 1 (8)

BLUE/BLACK 1 (7) J10

BLACK 1,5 (12) J8

BLUE/PINK 1 (8) J12

PURPLE 1 (6)

PURPLE/BLACK 1 (6) J14

BLACK 2,5 (17) J16

GREY 1,5 (5)

BLACK (11)

RED (11)

YELLOW 2,5 (4)

RED/GREEN 1 (16)

ALTERNATOR

RED 6 (21)

ORANGE 1,5 (19)

GREEN 1,5 (9)

GREY 2,5 (20)

RED 1,5 (14)

WHITE 1,5 (18)

ENGINE BLOCK

(OPIONAL)

(OPTIONAL)

BATTERY

SWITCH

AC-1

TO GENERATOR AC OUTPUT

BLUE (33)

BROWN (33)

CONTROL PANEL

TO REMOTE

BLACK 1,5 (23) J15

AIR FAN 1 AIR FAN 2

BLACK 1,5 (32) J11

230VAC

TO CONNECT BEFORE

FUSES AND BREAKERS

GENERATOR

THERMOSTAT

JUNCTIONBOX AIR FAN

FUEL LIFT

PUMP

GREY 1,5 (5)

BROWN 1,5 (31)

RED 2,5 (13)

GLOW (PREHEAT)

PLUGS

BROWN 4 (3)

Fig. 7: Lay out control PCB.

Page 15

EN / WHISPER 6 ULTRA Mobile / July 2004 15

hold

ct-2

ct-1

ct-2

gnd

tem

str.

exh

oil

reg

alt.

fuel

heat star t fuel fail

pull

AC-1

AC-2

LOCAL CONTROL PANEL

J28

3xPUMP OUTPUT

ALT

REGULATOR

J22

START/STOP

J8 J9

J10

J11

J12

J13

J14

J16

J15

J17

WCH/1

TAILOR MADE ENERGY

ALT-L

MASTERVOLT

3A 3A

10A

ALT

J24

J21

J23

J19

J18

SOLENOID

FUEL

WHITE (HOLD)

BLUE (COM.)

RED (PULL)

BATTERY

RED 25

12VDC

RED 2,5 (1)

BLACK 25

GROUND TO

BLACK 4 (2)J17

WATER TEMP.

SWITCH

GENERATOR TEMP.

SWITCH

OIL PRESS.

SWITCH

MOTOR

STARTER

CURRENT MESURING

TRANSFORMER

BLUE 1 (7)

BLUE/GREEN 1 (8)

BLUE/BLACK 1 (7) J10

BLACK 1,5 (12) J8

BLUE/PINK 1 (8) J12

PURPLE 1 (6)

PURPLE/BLACK 1 (6) J14

BLACK 2,5 (17) J16

GREY 1,5 (5)

BLACK (11)

RED (11)

YELLOW 2,5 (4)

RED/GREEN 1 (16)

ALTERNATOR

RED 6 (21)

ORANGE 1,5 (19)

GREEN 1,5 (9)

GREY 2,5 (20)

RED 1,5 (14)

WHITE 1,5 (18)

ENGINE BLOCK

(OPIONAL)

(OPTIONAL)

BATTERY

SWITCH

AC-1

TO GENERATOR AC OUTPUT

BLUE (33)

BROWN (33)

CONTROL PANEL

TO REMOTE

BLACK 1,5 (23) J15

AIR FAN 1 AIR FAN 2

BLACK 1,5 (32) J11

THERMOSTAT

JUNCTIONBOX AIR FAN

FUEL LIFT

PUMP

GREY 1,5 (5)

BROWN 1,5 (31)

RED 2,5 (13)

GLOW (PREHEAT)

PLUGS

BROWN 4 (3)

230VAC (110VAC)

IVO

(OPTIONAL)

CHARGER

BATTERY

24VDC

(OPIONAL)

(OPTIONAL)

CHARGER

IVO

230VAC (110VAC)

BATTERY

SWITCH

(OPTIONAL)

GROUND

BLACK 4

RED 4

2.5.15b Lay out control PCB 24V DC radiator fan

Page 16

16 July 2004 / WHISPER 6 ULTRA Mobile / EN

hold

ct-2

ct-1

ct-2

gnd

tem

str.

exh

oil

reg

alt.

fuel

heat start fuel fail

pull

AC-1

AC-2

LOCAL CONTROL PANEL

J28

3xPUMP OUTPUT

ALT

REGULATOR

J22

START/STOP

J8 J9

J10

J11

J12

J13

J14

J16

J15

J17

WCH/1

TAILOR MADE ENERGY

ALT-L

MASTERVOLT

3A 3A

10A

ALT

J24

J21

J23

J19

J18

SOLENOID

FUEL

WHITE (HOLD)

BLUE (COM.)

RED (PULL)

BATTERY

RED 25

12VDC

RED 2,5 (1)

BLACK 25

GROUND TO

BLACK 4 (2)J17

WATER TEMP.

SWITCH

GENERATOR TEMP.

SWITCH

OIL PRESS.

SWITCH

MOTOR

STARTER

CURRENT MESURING

TRANSFORMER

BLUE 1 (7)

BLUE/GREEN 1 (8)

BLUE/BLACK 1 (7) J10

BLACK 1,5 (12) J8

BLUE/PINK 1 (8) J12

PURPLE 1 (6)

PURPLE/BLACK 1 (6) J14

BLACK 2,5 (17) J16

GREY 1,5 (5)

BLACK (11)

RED (11)

YELLOW 2,5 (4)

RED/GREEN 1 (16)

ALTERNATOR

RED 6 (21)

ORANGE 1,5 (19)

GREEN 1,5 (9)

GREY 2,5 (20)

RED 1,5 (14)

WHITE 1,5 (18)

ENGINE BLOCK

(OPIONAL)

(OPTIONAL)

BATTERY

SWITCH

AC-1

TO GENERATOR AC OUTPUT

BLUE (33)

BROWN (33)

CONTROL PANEL

TO REMOTE

BLACK 1,5 (23) J15

AIR FAN 1 AIR FAN 2

BLACK 1,5 (32) J11

THERMOSTAT

JUNCTIONBOX AIR FAN

FUEL LIFT

PUMP

GREY 1,5 (5)

BROWN 1,5 (31)

RED 2,5 (13)

GLOW (PREHEAT)

PLUGS

BROWN 4 (3)

230VAC (110VAC)

IVO

(OPTIONAL)

CHARGER

RED 4

BLACK 4

2.5.15c Lay out control PCB 12V DC radiator fan

Page 17

EN / WHISPER 6 ULTRA Mobile / July 2004 17

2.5.16 Electrical diagram 230V 50Hz

INFORMATION

ROTOR

STATOR

230V 50Hz

EARTH AND NEUTRAL CONNECTED

EARTH AND NEUTRAL NOT CONNECTED

MAIN WINDING

(4)

(3)

MAIN WINDING

(2)

(3)

EXCITATION

(1)

WINDING

YELLOW/GREEN

DCC/AC-1

YELLOW/GREEN

BLUE (33)

BROWN (33)

BLUE

DCC/ct-1

(11)

RED

CURRENT TRANSFORMER

(11)

BLACK

CAPACITOR

BROWN

DCC/ct-1

(11)

RED

TRANSFORMER

(11)

BLACK

CURRENT

DCC/AC-1

YELLOW/GREEN

BLUE

YELLOW/GREEN

BROWN

BROWN (33)

BLUE (33)

Page 18

2.5.17a Diagram fan control 230V

18 July 2004 / WHISPER 6 ULTRA Mobile / EN

INFORMATION

TERMINAL BLOCK

GENERATOR CONTACT

PUMP (PCB)

THERMOSTAT GENERATOR

THERMOSTAT ENGINE

RADIATOR COOLER

GENERATOR

BATTERY

230VAC

ENGINE

- 12V

THERMOSTAT COOLER

PUMP +12V

BAT.

GENERATOR

FUSE 6,3A

230VAC (N)

FUSE 5A

BAT. +12V

230VAC (L1)

GENERATOR

FUSE 6,3A

RADIATOR COOLER

GENERATOR

RADIATOR COOLERRADIATOR COOLER

ENGINE

FUSE 5A FUSE 5

POWER SUPPLY 230 VAC

ENGINE GENERATOR

DIMENTION BOX: 270x270x180 MM

JUNCTION BOX AIR FANS

12VDC

230VAC

12VDC K1 K2

230/115VAC 200VA

TRAFO

230VAC

230V

400V

CU1,5

+1-

CU0,75

80-70?C

CU0,75

45-35?C

CU0,75

35A45 87

CU1,5

230VAC

CU1.5

6,3A116,3A

12 1413 15

45-35?C80-70?C

CU1.5

230VAC

TRAFO

200VA

230/115VAC

110V

120V

115V

141211

230VAC

BREAKER

CIRCUIT

AIRFAN

GENERATOR

AIRFAN

BREAKER

CIRCUIT

MAIN

Page 19

EN / WHISPER 6 ULTRA Mobile / July 2004 19

PUMP (PCB)

GENERATOR CONTACT

THERMOSTAT ALTERNATOR

THERMOSTAT ENGINE

ALTERNATOR

RADIATOR COOLER

ENGINE

BATTERY

TERMINAL BLOCK

THERMOSTAT COOLER

ALTERNATOR

+ BAT.

FUSE

JUCTION BOX AIR FANS

FUSE

CONTROL PANEL

RADIATOR COOLER

ALTERNATOR

PUMP 2

- BAT.

ENGINE ENGINE

CU0,75

80-70∞C

CU4

CU0,75

45-35∞C

CU0,75

+1-2-

356+7

CU2,5

CU2.5

-8+9-

80-70∞C

45-35∞C

20/40A

21435768

DIMENIONS BOX: 160x160x90 MM

2.5.17b Diagram fan control 12V / 24V

Page 20

20 July 2004 / WHISPER 6 ULTRA Mobile / EN

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, and connecting

the battery to earth.

3.2 OPERATION INSTRUCTIONS

3.2.1 Summarised operating instructions (daily use)

Routine "pre-start" checks:

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

2 Check cooling system (coolant levels).

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 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.

4 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 Switch to another 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 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 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, 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 coolant in both expansion tanks

3 Check for leakage’s.

4 If no MASTERSWITCH is used: Switch main Power

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

vices.

5 Switch on the battery switch.

1 2

Fig. 10.

1 Max. oil level;

2 Min. oil level.

Page 21

EN / WHISPER 6 ULTRA Mobile / July 2004 21

OPERATION

Starting the generator:

By pushing the start button briefly the electric system

is activated 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 starting the engine while

already running which could cause damage.

Checks once the generator is in operation:

1 Check for abnormal noise or vibration.

2 Check the voltage.

3 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:

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 expectancy,

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.

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 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 generator abruptly after a long

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

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 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 but-

ton, otherwise it will drain the start battery.

Page 22

22 July 2004 / WHISPER 6 ULTRA Mobile / EN

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 carried when the enclo-

sure is open. When oil and dirt has 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

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 correct functioning release the

bleedscrew on the high pressure fuel pump. Push the

glow button activating the electric system and activating

the fuelpump. Retighten the bleed screw when no further

air bubbles are expelled.

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. 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 Replacing the oil filter

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

has to be carried out according to the schedule in this

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

tissues under the filter.

Fig. 11: Bleeding fuel lines.

1= fuel bleeding screw

Fig. 12.

Page 23

EN / WHISPER 6 ULTRA Mobile / July 2004 23

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 for readjustment of the V-

belt. Deflections 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.

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 page 65; 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 and readjust V-belt.

EVERY 100 HOURS:

• Change oil.

• Check the battery acid level.

• Check battery terminals for corrosion

• Check and readjust V-belt.

EVERY 300 HOURS:

• Check the impeller of the 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 500 HOURS:

• Replace the impeller of the water pump.

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 i.e. anti

clockwise looking at the impeller.

10 mm

Fig. 14.

1 2

1 Max. oil level;

2 Min. oil level.

Fig. 13.

Fig. 15.

MAINTENANCE

Page 24

24 July 2004 / WHISPER 6 ULTRA Mobile / EN

TROUBLE SHOOTING

EVERY 1000 HOURS:

• Replace the V-belt.

• Retighten cylinder head bolts/adjust +

valve clearance.

• Check and clean the vadiators.

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.

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 The coolant can stay in the engine and radiators.

5 Disconnect the battery and store it in a place dry and

free of frost 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 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 the level of the cooling liquid daily

Retighten cylinderhead bolts , change oil, replace oil filter

and readjust valve clearance after first 50 hours

Changing oil 100 hours

Check and readjust V-belt 100 hours

Replace the oil filter 300 hours

Check impeller waterpump 300 hours

Checking valve clearance 300 hours

Replacing fuel filter 300 hours

Replace impeller waterpump 500 hours

Clean radiator with compressed air 1000 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 25

EN / WHISPER 6 ULTRA Mobile / July 2004 25

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 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 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 1500 RPM (50

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 1575 RPM = 52.5 Hz . Under

no circumstances should the RPM be under full load

below 1470 RPM = 49 Hz.

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

finding paragraph. Digital Diesel Control 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 6 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 210/105V). • 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 210/ • Engine is not reaching the rated RPM. Switch off a load; (part off ) consumers. 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 245/130V). procedures).

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

capacitors. necessary.

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

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

• Defective voltageregulator Replace voltage regulator

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.

MAINTENANCE

Page 26

26 July 2004 / WHISPER 6 ULTRA Mobile / EN

TROUBLE SHOOTING

PROBLEM CAUSE SOLUTION

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 The problem must be an electric malfunction. the starter makes clicking in the connection between battery noises, or the engine cranks and starter.

Display will indicate “Low Start Bat”

• 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).

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 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.

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 Alternator 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 27

EN / WHISPER 6 ULTRA Mobile / July 2004 27

• 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 carbon 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 carbon, the generator system is not properly used. and is running for long periods at too low load.

• 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 piping; inspect manifold inside.

• 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.

• Choked exhaust system, exhaust blocked. Check the exhaust piping; inspect the manifold and mufflers inside.

• 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.

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 faulty solenoid or DDC unit.

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.

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. Digital Diesel Control will identify failure

TROUBLE SHOOTING

Page 28

28 July 2004 / WHISPER 6 ULTRA Mobile / EN

TROUBLE SHOOTING

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 liquid level expansion tanks; water

(thermo-switch tripped). pump: impeller: coolant flow.

• Impeller broken. Check if radiator fans work properly and switch to

• Cooling water blocked. higher speed. Air in piping system can block circulation. Almost all problems of oeverheating are caused by faulty installation: bents in the routing of cooling pipes that captures airbubbles (air locks) or hot air circulating back into the radiators. Refer to installation manual.

• Air or water in the fuel. Check and clean

• 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.

• 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.

• Broken impeller. Clean radiator.

• Radiator choked by dirt. Check and refer to installation manual.

• Hot air circulation in radiator

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

• Faulty thermostat. Check the thermostat or replace.

Page 29

EN / WHISPER 6 ULTRA Mobile / July 2004 29

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 out of service for a long period

or a short circuit. This can be solved by charging the ca-

pacitor ("flashing") independently by a small 9 Volt bat-

tery. 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.

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 6 ULTRA 50Hz-230V

• Resistance both main stator windings 0.77 Ohm

in series

• Resistance both rotor windings 2,00 Ohm

• Resistance exciter stator winding 1.91 Ohm

5.3.4 Meggering

One can try to measure resistance between the housing and

the windings with 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

Fig. 16.

DIODE

Fig. 17.

TROUBLE SHOOTING

Page 30

30 July 2004 / WHISPER 6 ULTRA Mobile / EN

TROUBLE SHOOTING

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 1500 RPM (50 Hz). A RPM drop of 5% at full

load is acceptable. Therefore a no load setting should be

at + 1575 RPM = 52.5 Hz.

Under no circumstances should the RPM be under full

load below 1470 RPM = 49 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 have to be carried out with a cold

engine. When both procedures are carried out be sure to

retighten the cylinder head bolts before adjusting the

valve clearance.

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: M10 bolt 75-85 Nm

M8 bolt 20-30 Nm

Rocker stay tightening torque: M8 bolt 15-22 Nm

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 (notch) on the crankshaft pulley

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

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

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 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 turn the crankshaft

240 degrees clockwise from the T.D.C of cylinder 1 to the

T.D.C of cylinder 3. Position 2 fig. 20 against the notch.

Adjusts the valves of cylinder 3 and turn the crankshaft

240 degrees further clockwise to the T.D.C of cylinder 2

and adjust the valves; position 3 fig. 20 against the notch.

5.4.3 Disassembling instructions

It could be necessary to disassemble the generating set

for repair or checks.

Following instructions will help:

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

and cable connections have to be taken off. The set

is fixed to its base by four rubber mountings and can

be loosened by removing the four nuts from the bolts

of these mountings. Moreover the generating set is

fixed by 2 fail safes that prevent the generating set

from getting loose if the rubber mountings should

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. 5 nuts are

well accesible. The sixth nut has to be removed by

taking out the bold from the bottom of the canopy.

Fig. 18.

2= adjustment screw RPM

3= manual stop

11 7 5

946

213

Fig. 19.

Fig. 20.

Page 31

EN / WHISPER 6 ULTRA Mobile / July 2004 31

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

sule is by lifting the set with the aid of the lifting eye

and taking away the capsule downwards.

3 The cooler elements are welded to the alternator hou-

sing with silver and cannot be disassembled. How-

ever one can take off the complete alternator hou-

sing.

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

out the fitting to the oil heatexchanger to be able to

take off the aluminium housing. All cables and wiring

have to be taken loose first.

5 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 185-mm length and a

M10 bolt.

6 Reassembling the generating set one should take

care for alignment cleaning the surfaces between en-

gine and alternator and tighten the bolts crosswise

and gradually.

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

be cleaned and made free of oil and grease.

8 Test the generating set first outside its capsule and

check very carefully for leakages before putting it

back in its enclosure.

TROUBLE SHOOTING

Page 32

32 July 2004 / WHISPER 6 ULTRA Mobile / EN

SPARES

6 SPARES

A complete parts manual in English is available as an option number: 50200382.

A work shop manual in English is available as an option number: 50200171.

We recommend the following spares for service and maintenance.

• Kit A: parts for regular maintenance parts marked (*) article no 50201860

• Kit B: parts for maintenance + spare parts: all parts market (*)+(**) article no 50201761

ARTICLE NO DESCRIPTION

50209030 Fuel filter (*) 50201031 Fuel lift pump 50203120 V-belt (*) 50203121 Oilfilter (*) 50201850 Water pump complete Mastervolt type M (refer to fig. 21) 50209011 Impeller + gasket (*) (4,3,5) 50201812 Cover type M (**) (2) 50209018 Bolts cover (**) (1) (6 pcs.) 50201851 Pump repair kit A consisting of: Shaft (13), Bearings (2 pcs) (10), O-ring (9), Seals (2 pcs.) (8),

Clips (1 set) (11, 12), O-ring (14) 50209010 Pump repair kit B (**)(same as repair kit A excluding the shaft (13) and O-ring (14)) 50201060 Capacitor xx micro-farad, 2 pcs (**) (xx = give value when ordering) 50209132 Measuring coil (**) 50201890 Rotary diode (**) 50201886 Alternator bearing including O-ring (**) 50209140 Voltage regulator (optional) 50209104 Local control panel (**) 50212170 Fuses 10 Amps(*) 50212154 Fuses 3 Amps (*) 50209100 Digital Diesel Control unit 50201866 Wiring loom complete (***) 50209102 Remote control unit 130010915 Cable remote control 15 mtr, including connectors 50204033 Overhaul gasket kit / seal kit 50204030 Cylinder head gasket kit 50203040 Glow plug, 3pcs (**) 50203050 Nozzle injector, 3pcs (**) 50204160 Fuel pump (high pressure) complete 50203045 Thermostat (**) 50203038 Gasket thermostat (**) 50204037 Gasket rocker cover (**)

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

Page 33

EN / WHISPER 6 ULTRA Mobile / July 2004 33

Spare parts water pump type M, article no 50201850:

no description article no

1 screw cover, 6x 50209018

2 cover type M, 1x 50201812

3 screw impeller, 1x refer to impeller

4 Impeller (1x), including screw (3) 50209013

5 Gasket, 1x 50209012

6 Pump housing, 1x 50201813

8 Seal, 2x 50209015

9 O-ring, 1x 50209017

10 Bearing, 2x 50209014

11 Clip, 2x 50209019

12 Clip, 1x 50209016

13 Shaft type M 1x 50201811

14 O-ring, 1x 50201814

15 Clamp, 4x 50201815

Impeller kit: impeller + gasket + screw

M12

Fig. 21: Water pump type M.

TROUBLE SHOOTING

Page 34

34 July 2004 / WHISPER 6 ULTRA Mobile / EN

INFORMATION LOG

first service after 50 hours: hour counter: remarks:

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

Page 35

EN / WHISPER 6 ULTRA Mobile / July 2004 35

NOTES

Page 36

36 July 2004 / WHISPER 6 ULTRA Mobile / EN

MASTERVOLT

Snijdersbergweg 93, 1105 AN Amsterdam, The Netherlands

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

www.mastervolt.com / info@mastervolt.com