Whisper Power W-GV/2, W-GV 8, W-GV/3, W-GV 10, W-GV 15 User Manual

V1.2, June 2017

USER’S MANUAL

W-GV/2, W-GV/3, W-GV/3+,

W-GV 8, W-GV 10 and W-GV 15

genverters for mobile use

WHISPERPOWER BV
Kelvinlaan 82
9207 JB Drachten
Netherlands
Tel.: [phone]
Fax.: [phone]
www.whisperpower.com

Art.nr. 40200981

CONTENTS

2 W-GV/2, W-GV/3, W-GV/3+, W-GV 8, W-GV 10 and W-GV 15 — June 2017 — EN

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 Identification plate ............................................................................................................................................. 4

2 GENERAL INFORMATION ............................................................................................................................................................ 5

2.1 Safety .................................................................................................................................................................................... 5

2.1.1 Warnings and symbols ....................................................................................................................................... 5

2.1.2 General .............................................................................................................................................................. 5

2.1.3 Organizational measures ................................................................................................................................... 5

2.1.4 Maintenance & repair ........................................................................................................................................ 5

2.1.5 Electrical safety .................................................................................................................................................. 6

2.1.6 Magnetism ......................................................................................................................................................... 6

2.1.7 Operation ........................................................................................................................................................... 6

2.1.8 Fire and explosion .............................................................................................................................................. 6

2.1.9 Chemicals ........................................................................................................................................................... 6

2.2 Transport, lifting and storage ............................................................................................................................................... 6

2.3 Features ................................................................................................................................................................................ 7

2.3.1 General .............................................................................................................................................................. 7

2.3.2 Construction ...................................................................................................................................................... 7

2.3.3 Control ............................................................................................................................................................... 7

2.3.4 Installation ......................................................................................................................................................... 7

2.3.5 Documentation .................................................................................................................................................. 7

2.4 Main components to identify ............................................................................................................................................... 8

2.4.1 W-GV/2 and W-GV 8, W-GV/3 and W-GV 10 ..................................................................................................... 8

2.4.2 W-GV/3+ and W-GV 15 ...................................................................................................................................... 9

3 TECHNICAL INFORMATION ....................................................................................................................................................... 10

3.1 Explanation of functional parts .......................................................................................................................................... 10

3.1.1 Control system ................................................................................................................................................. 10

3.1.2 AC Permanent Magnet Alternator ................................................................................................................... 10

3.1.3 Engine .............................................................................................................................................................. 10

3.1.4 Starter battery charging ................................................................................................................................... 10

3.1.5 Alarms and shut-down ..................................................................................................................................... 10

3.1.6 Control ............................................................................................................................................................. 10

3.1.7 Remote control panel ...................................................................................................................................... 10

3.1.8 Load indicator .................................................................................................................................................. 10

3.1.9 Fuel .................................................................................................................................................................. 11

3.1.10 Bio-diesel ......................................................................................................................................................... 11

3.1.11 Lubricating oil .................................................................................................................................................. 11

3.1.12 Cooling liquid ................................................................................................................................................... 11

3.2 Technical data .................................................................................................................................................................... 12

3.2.1 Kubota-based models ...................................................................................................................................... 12

3.2.2 Mitsubishi-based models ................................................................................................................................. 14

4 OPERATION .............................................................................................................................................................................. 16

4.1 General ............................................................................................................................................................................... 16

4.2 Programmable speed ......................................................................................................................................................... 16

4.3 Operating instructions ........................................................................................................................................................ 16

4.3.1 Daily check of oil level ...................................................................................................................................... 16

4.3.2 Summarized operating instructions (daily use) ............................................................................................... 16

4.3.3 Extended operating instructions ...................................................................................................................... 16

5 MAINTENANCE ......................................................................................................................................................................... 18

5.1 Maintenance intervals ........................................................................................................................................................ 18

5.2 Alternator ........................................................................................................................................................................... 18

5.3 Engine ................................................................................................................................................................................. 18

5.3.1 Preliminary instructions ................................................................................................................................... 18

5.3.2 Bleeding the fuel lines...................................................................................................................................... 18

5.4 Regular maintenance.......................................................................................................................................................... 18

5.4.1 General precautions ........................................................................................................................................ 18

CONTENTS

W-GV/2, W-GV/3, W-GV/3+, W-GV 8, W-GV 10 and W-GV 15 — June 2017 — EN 3

5.4.2 Servicing after break-in .................................................................................................................................... 19

5.4.3 Changing engine oil and oil filter cartridge ...................................................................................................... 19

5.4.4 Checking the battery ........................................................................................................................................ 19

5.4.5 Adjusting the V-belt tension ............................................................................................................................ 19

5.4.6 Draining water from the fuel tank ................................................................................................................... 20

5.4.7 Replacing the fuel filter .................................................................................................................................... 20

5.4.8 Changing the air filter element ........................................................................................................................ 20

5.4.9 Checking hoses and electrical connections ...................................................................................................... 20

5.4.10 Servicing after 800 hours and beyond ............................................................................................................. 20

5.5 Putting out of service ......................................................................................................................................................... 20

6 TROUBLESHOOTING ................................................................................................................................................................. 21

6.1 General ............................................................................................................................................................................... 21

6.1.1 Failure codes .................................................................................................................................................... 21

6.2 Alternator/ electrical faults ................................................................................................................................................ 21

6.2.1 Troubleshooting table for alternator ............................................................................................................... 22

6.2 Engine faults ....................................................................................................................................................................... 22

6.2.1 General ............................................................................................................................................................ 22

6.2.2 Troubleshooting table for engine .................................................................................................................... 22

6.2.3 Warnings .......................................................................................................................................................... 25

6.2.4 Service address ................................................................................................................................................ 25

7 SPARE PARTS ............................................................................................................................................................................ 26

8 OTHER PRODUCTS FROM WHISPERPOWER............................................................................................................................... 27

Maintenance log .................................................................................................................................................................................. 28

Supplier’s Declaration of Conformity/Incorporation

GENERAL INFORMATION

4 W-GV/2, W-GV/3, W-GV/3+, W-GV 8, W-GV 10 and W-GV 15 — June 2017 — EN

1 INTRODUCTION

1.1 GENERAL

This manual serves as a guideline for the safe and effective
operation, maintenance and possible correction of minor
malfunctions of the two and three cylinder Genverters for
mobile applications manufactured and marketed by
WhisperPower.

It is therefore essential that every person who works on or with
the Genverters should be familiar with the contents of this
manual, and that he/she should carefully follow the instructions
contained herein. Both safety and durability depend very much
on the correct identification, installation and the correct
understanding of ratings, features, design, maintenance and
operation procedures.

The information, specifications, illustrations and statements
contained within this publication are given with our best
intentions and are believed to be correct at the time of going to
press.

All of the specifications, provisions and instructions contained
in this manual apply solely to standard versions of the standard
versions of the two and three cylinder Genverters delivered by
WhisperPower.

This manual is valid for the following models:

For other models see other manuals available on our website:
www.whisperpower.com.

Our policy is one of continued development and we reserve the
right to amend any technical information without prior notice.

Whilst every effort is made to ensure the accuracy of the
particulars contained within this publication neither the
manufacturer nor the distributor or dealer in any circumstances
shall be held liable for any inaccuracy or for the consequences
thereof.

1.2 SERVICE AND MAINTENANCE

Regular service and maintenance should be carried out
according to the directions in this manual. For service and
maintenance, turn to the manufacturer or a dealer.

1.3 GUARANTEE

WhisperPower guarantees that this Genverter has been built
according to the principles of 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 Genverters
are tested and inspected.

This Genverter’s correct operation is subject to guarantee. The
period and conditions of this guarantee are laid down in the
general conditions of delivery as registered with the Chamber
of Commerce and Industries for the North of the Netherlands
number 01120025 and are available on request. The guarantee
period is two years, limited to 1000 running hours.

Guarantee does not cover failures caused by misuse, neglect or
faulty installation.

1.4 LIABILITY

WhisperPower does not accept responsibility for damage,
injuries or casualties which are the result of operation of the
Genverter in specific conditions bringing dangers which could
not be foreseen, or could be avoided by additional measures.
WhisperPower does not accept liability for damage due to use
of the Genverter, possible errors in the manuals and the results
thereof.

Automatic start/stop: WhisperPower cannot be
held responsible for damage caused by the
Genverter running unattended using the auto­start/stop mode or interval mode.

Do not use the Genverter when the vehicle is
inside a building or in other enclosed areas. Be
aware using the Genverter in wind still
conditions, when the exhaust fumes could
accumulate under, around or even in the vehicle.

SWITCH OFF THE GENVERTER WHEN THE
VEHICLE IS INSIDE BUILDINGS OR IN ENCLOSED
AREAS.

1.5 IDENTIFICATION

1.5.1 Identification plate

All required identification data are on the identification plate.
The identification plate also mentions some basic features of
the Genverter.

SERIAL NUMBER
The identity of the Genverter is given by the SERIAL NUMBER.
Using this number, the manufacturer can trace the
specifications of the Genverter.

POWER
The identification plate gives the maximum load in kVA (=kW)
calculated with power factor one. When calculating a load one
should always take into account the power factor or cos. phi of
this load. The resulting load should not exceed the nominal
power as shown on the identification plate. Power is rated at an
ambient temperature of 25°C. For higher temperatures the
Genverter has to be de-rated. If the radiator fan (12V fan) is
driven using power generated by the Genverter, the net power
may be less than specified on the identification plate.

Part no.

Description

41001120

W-GV/2 K (Kubota Z482)

41001220

W-GV/2 M (Mitsubishi L2E)*

41005020

W-GV8 (Kubota Z482)

41001320

W-GV/3 K (Kubota D722)

41001420

W-GV/3 M (Mitsubishi L3E)*

41009020

W-GV10 (Kubota D722)

41001520

W-GV/3+ (Kubota D1105)

41007020

W-GV 15 (Kubota D1105)

* Several sections, in particular 2.4 and 5.4, are pending
revision in order to take into account specific characteristics for
Mitsubishi-based models.

GENERAL INFORMATION

W-GV/2, W-GV/3, W-GV/3+, W-GV 8, W-GV 10 and W-GV 15 — June 2017 — EN 5

Figure 1: Identification plate

VOLTAGE
The Permanent Magnet Alternator (PMA) generates a variable
voltage between 250V and 400V. Depending on the type of
installation, this is converted by a DC PowerCube or an AC
Power Module for Genverter

FREQUENCY
The Permanent Magnet Alternator output frequency is
considerably higher than in in common alternating current
installation. The DC PowerCube and WP-PMG (Power Module
for Genverter), however, are designed to generate very stable
DC and AC outputs from the PMA output.

CURRENT
The maximum allowed current at the specified voltage and
power factor.

PHASE
The number of live wires running from the genverter.

WEIGHT
The net dry weight (approximately) in kg. This is without fuel,
oil, cooling liquid, packaging and external installation
equipment.

CE-MARKING
The “CE” symbol shows that the Genverter is built according to
European Community safety regulations. Refer to EC
Declaration of Conformity for more details.

Safety is also a matter of installation, utilization and operating
conditions. See also 2.1.

It is recommended to consult the manufacturer before
changing a factory setting. If the Genverter involved is not new,
former users may have changed the settings. Check the settings
when there is any doubt.

2 GENERAL INFORMATION

2.1 SAFETY

2.1.1 Warnings and symbols

Safety instructions and warnings are marked in this manual by
the following pictograms, indicating that a piece of equipment,
routine, circumstance, procedure, etc. deserves extra attention:

WARNING
This 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.

WARNING
This symbol indicates that a potential hazard
exists caused by moving parts and draws
attention to special warnings, instructions or
procedures which, if not strictly observed, may
result in severe personal injury or loss of life.

WARNING
This danger symbol refers to toxic danger caused
by Carbon monoxide (CO) and draws attention to
special warnings, instructions or procedures
which, if not strictly observed, may result in
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.

2.1.2 General

When correctly installed and used in normal circumstances this
Genverter fulfils EC safety regulations. This Genverter 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. Refer to the Declaration of Conformity in this manual.

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

2.1.3 Organizational measures

The user must always:

 have access to the user's manual;
 be familiar with the contents of this manual. This

applies in particular to this chapter, Safety Guidelines
and Measures.

2.1.4 Maintenance & repair

WARNING

When service has to be carried out while the
engine is running, be aware of moving parts.

If the W-GV4 Scalino is switched off during maintenance and/or
repair activities, it should be secured against unexpected and
unintentional switching on:

 remove the AC supply;

GENERAL INFORMATION

6 W-GV/2, W-GV/3, W-GV/3+, W-GV 8, W-GV 10 and W-GV 15 — June 2017 — EN

 remove the connection to the batteries;
 be sure that third parties cannot reverse the

measures taken.

If maintenance and repairs are required, use original spare
parts only.

Always consult the manual before carrying out maintenance.

2.1.5 Electrical safety

Warning signs indicate parts which could be live.

 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.

2.1.6 Magnetism

WARNING!
The genverter incorporates powerful permanent
magnets. Cardiac patients, especially those living
with a pacemaker, should bear this in mind.

2.1.7 Operation

There are no external moving parts like fans and V-belts. The
hot parts of the engine are covered by the sound shield and
therefore the W-GV4 Scalino is very safe when the sound shield
is closed.

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

 The Genverter should be operated by authorized

personnel only.

 Be aware of hot parts and especially parts of the

exhaust system and the cooling system.

 If the Genverter is unsafe, fit danger notices and

disconnect the battery positive (+) lead so that it
cannot be started until the condition is corrected.

 Do not attempt to operate the Genverter with a

known unsafe condition. Disconnect the battery
positive (+) lead prior to attempting any repairs or
cleaning inside the enclosure.

 Always consult the manual before carrying out

maintenance.

 Do not change the settings without consulting the

manufacturer. Keep a record of setting changes in this
manual.

2.1.8 Fire and explosion

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

WARNING
Never use the M-GV4 Piccolo in situations where
there is danger of gas or dust explosion or
potentially flammable products!

 Avoid refilling the fuel tank while the engine is

running. When oil or fuel is leaking do not use the
GV4 Scalino.

 Hydrogen gas possibly generated by batteries being

charged is explosive. Ensure proper ventilation. Do
not smoke or allow sparks, flames, or other sources of
ignition around batteries.

 Keep a fire extinguisher on hand.

2.1.9 Chemicals

 Fuels, oils, coolants, and battery electrolyte can be

hazardous 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.

 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 Genverter avoid any risk of personal injuries,
do not stand under the Genverter.

 Use soft slings to avoid damage
 On the engine is a lifting hoist eye which can be used

to take the Genverter out of the capsule. It can also
be used to lift the complete Genverter including the
capsule.

 After transporting the Genverter 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

minimize condensation, store the Genverter in a dry
and warm storage area.

 Follow the battery manufacturer’s instructions when

storing the battery.

GENERAL INFORMATION

W-GV/2, W-GV/3, W-GV/3+, W-GV 8, W-GV 10 and W-GV 15 — June 2017 — EN 7

2.3 FEATURES

2.3.1 General

The WhisperPower two and three cylinder Genverters combine
2 and 3 cylinder engines with highly efficient Permanent
Magnet alternators. The voltages and frequencies produced,
however, require Genverters to be connected to WhisperPower
PowerCubes or Power Modules producing clean DC or AC
output, as applicable. This is an original concept, which is cost­effective as wells as easy on installation.

2.3.2 Construction

The Genverter incorporates a diesel engine which has a
permanent magnet alternator in the flywheel. The engine is
mounted on a steel base frame and mounted securely on a
double set of anti-vibration mounting pads in a sound
attenuated canopy. The output of the power from the
alternator will be from zero to 300V-400Hz and 400V-500Hz,
depending on the engine speed. The engine speed is set to
strike a balance between fuel efficiency and comfort. All cables
and hoses are guided through the capsule’s sides.

2.3.3 Control

The Digital Control system of the Genverter is based on
microprocessor technology. Several operating modes and
automatic start/stop functions can be programmed and
monitored (refer to Digital Diesel Control user’s manual).

All functions can be set from the remote control panel, which
comes as standard with the Genverter, including a 15 m cable.

2.3.4 Installation

The Genverter is not self-contained and is only operable after
proper installation using additional accessories and installation
materials such as a starter battery, fuel supply and an exhaust
system.

Installation accessories are listed in the installation manual and
are available through the supplier of the Genverter.

2.3.5 Documentation

Included in the delivery are:

 This user’s manual (number: 40200981).
 An installation manual (number: 40200991).
 A DDC operating manual (no. 40200801).
 A DDC quick reference guide (no. 40200142).

The user’s manual contains a list of important maintenance and
spare parts as well as a chapter on maintenance and problem
solving. Manuals in other languages are available on request.

GENERAL INFORMATION

8 W-GV/2, W-GV/3, W-GV/3+, W-GV 8, W-GV 10 and W-GV 15 — June 2017 — EN

2.4 MAIN COMPONENTS TO IDENTIFY

2.4.1 W-GV/2 and W-GV 8, W-GV/3 and W-GV 10

The figures below apply to Mitsubishi-based two- and three-cylinder genverters, which are all very similar.
NOTE: Kubota-based versions are under development.

1. oil dipstick

2. oil filter

3. fuel injection pump

4. stop solenoid

5. fuel line to injector

6. local control panel

7. coolant filler cap

8. oil filler cap

9. thermostat cover (coolant
temperature sensor behind)

10. V-belt

11. speed control lever and
stop lever (behind bar)

Figure 2: W-GV/2 and W-GV 8, W-GV/3 and W-GV 10, service side

1. starter

4. alternator

3. air filter housing

4. Digital Diesel Control

5. Permanent Magnet
Alternator

6. earth lug

7. exhaust

Figure 3: W-GV/2 and W-GV 8, W-GV/3 and W-GV 10, reverse view

11

10 9 8 6 4

3

2

5 1 3

1

4

2

5

6

7
7

GENERAL INFORMATION

W-GV/2, W-GV/3, W-GV/3+, W-GV 8, W-GV 10 and W-GV 15 — June 2017 — EN 9

2.4.2 W-GV/3+ and W-GV 15

1. manual lift pump

2. manual stop lever

3. speed control lever

4. oil dipstick

5. stop solenoid

6. fuel injection pump

7. injector

8. coolant filler cap

9. oil filler cap

10. thermostat cover (coolant
temperature sensor behind)

11. V-belt

12. oil filter

Figure 4: W-GV/3+ and W-GV 15, service side

1. starter

2. oil filter

3. oil pressure switch

4. alternator

5. air filter

6. Permanent Magnet
Alternator

7. earth lug

8. exhaust

Figure 5: W-GV/3+ and W-GV 15, reverse view

12

11

10 9 8

7 6 5

4

3 2 1

1

2

3

4

6

7

8

5

TECHNICAL INFORMATION

M-GV/2, M-GV/3, M-GV 8 and M-GV 10 — March 2015 — EN 10

3 TECHNICAL INFORMATION

3.1 EXPLANATION OF FUNCTIONAL PARTS

The WhisperPower two and three cylinder Genverters are
highly advanced systems. They combine new technologies from
various fields such as engine technology, PM alternator
technology and, in the PowerCubes and Power Modules,
inverter technology.

3.1.1 Control system

The engine is monitored and controlled by microprocessors in
the Digital Diesel Control system (DDC). The standard electrical
engine control system is 12 Volt negative earth. Non-earth
return (ungrounded) is available as option. Check your
identification data to determine which system is being used.
Either system is of the "energize to run" type: it stops when the
12 V DC voltage is taken away. Highly advanced, the DDC
controls the engine and also operates as a management system
to control the engine in combination with the PowerCube.

3.1.2 AC Permanent Magnet Alternator

The Three Phase Permanent Magnet Alternator is incorporated
in the flywheel and has a very high efficiency of at least 94%.
The output of the power from the alternator will be between
250V-300Hz and 400V-500Hz, depending on the engine speed.
As the efficiency is very high, little cooling is needed. The
alternator and the engine use the same cooling system.

3.1.3 Engine

The Genverter has a Kubota engine fine-tuned by
WhisperPower. The engine has indirect injection and was
designed to meet the highest emission standards. The cooling
system can be used for CHP (Combined Heat and Power
production). Contact WhisperPower for additional information.

Further details are in the data sheet in 3.2.

3.1.4 Starter battery charging

The engine is equipped with a 12.5A (two-cylinder version) or
40A (three-cylinder version) alternator for charging the starter
battery. The voltage is regulated at ±14.4V.

3.1.5 Alarms and shut-down

In the event of malfunctioning this will be indicated by the
failure light, details will be shown on the display and the engine
will be shut down. Two parameters are being monitored: oil
pressure and oil temperature.

All alarm switches are closed when no malfunction occur. A
contact is cut in the event of an alarm. This means that the
Genverter will not work when the alarm switches are broken or
when there is a loose wire. The system therefore is intrinsically
safe. The panel will display details about the alarm.

3.1.6 Control

The Genverter can be operated by push buttons on the panel
on the unit or on the remote control. Pushing the START button
will activate the control system and will start the engine
automatically. Pushing the STOP button will stop the engine and
the electrical system will be deactivated. When using the
Genverter in an automatic mode the engine will start when

power is demanded, e.g. because of low batteries or another
“event” that triggers the starting operation. Various automatic
modes are available through the remote control panel. Refer to
the DDC Operating manual for more information.

Figure 6: Local control panel

3.1.7 Remote control panel

The remote control panel is used to make the various settings.
It also displays parameters such as Voltage, Hz, Amps, and
many others (refer to the DDC manual for details).

The connection between the remote control panel and the
Genverter control unit is made using plug-in connectors. A 10 m
communication cable is in the standard supply. If necessary, a
longer or shorter cable can be supplied. Multiple remote
control units can be put in parallel by using the connectors on
the back of the units (refer to installation instructions).

Figure 7: Digital diesel remote control panel

1. Start button

2. Stop button

3. Select button

4. Set button

5. Failure lamp

6. Generator load indicator

7. Display

3.1.8 Load indicator

On the local panel and on the remote control the load will be
indicated on the display and/or by the LED bar.

1

2

6

5

3 4 7

TECHNICAL INFORMATION

W-GV/2, W-GV/3, W-GV/3+, W-GV 8, W-GV 10 and W-GV 15 — June 2017 — EN 11

3.1.9 Fuel

Specification

The engine must only be used with diesel fuel oil conforming to
the standards for use in modern diesel engines. It is essential
that the fuel should be free from water and contaminants. The
following specifications must be complied with:

Diesel Fuel Specification

Location

EN590:96

European Union

BS 2869-A1 0r A2

UK

No. 2-R, No 1-D, ASTM D975-94

USA

GB252

China

ISO 8217 DMX

International

JIS K2204 Grade No.2

Japan

KSM-2610

South-Korea

Diesel pre-heater

Optionally, a diesel pre-heater can be installed. This is a useful
feature in extremely cold conditions. In this case the fuel filter
will be inside the canopy and there will be a heating element
upstream of the filter preventing the formation of paraffin
crystals in the diesel and clogged filters as a result. The system’s
operation is temperature-dependent and is controlled by a
separate switch to turn it “on” or “off”.

3.1.10 Bio-diesel

The use of diesel fuels to a maximum blend of 5% (by volume)
of Fatty Acid Methyl Esters (FAME) known on the market as B5
diesels is allowed as far as these fuels comply with EN 14214
(Europe) or ASTM D-6751 (USA), as appropriate.

Bio-fuels should be supplied by recognized and authorized
suppliers only. ”Self-blended fuels” may cause engine damage
and will affect warranty.

Please note that free methanol in FAME may result in corrosion
of aluminium parts. Free water in FAME may result in choked
fuel filters and injectors and may result in increased bacterial
growth.

3.1.11 Lubricating oil

1 Specification:

The oil must be suitable for oil changes as specified in the
maintenance chapter. The engine must be run on heavy duty
lubricating oil meeting the requirements of API class CF, CF-4,
CH-4, CI-4 or CI-4 plus . It is recommended to use lubricating oil
from WhisperPower or a well-known brand.

It is very important to use the correct oil
specification. Do not mix different types of oil.
Higher API class oils and synthetic oils are to be
avoided.

2 Oil viscosity:

We recommend 10W40 multi grade oil. In very cold or hot
conditions, a special grade could be applied according to the
Viscosity Chart below:

Figure 8: Viscosity chart

3 Oil capacity:

The content of the crankcase and oil filter, is as specified below
(approximate data):

GV/2 Kubota

2.8 L

GV/2 Mitsubishi

3.2 L

GV/3 Kubota

4.1 L

GV/3 Mitsubishi

4.4 L

GV/3+ Kubota

5.1 L

Do not overfill with lubricating oil as this may
have a detrimental effect on engine
performance.

4 Lubricating oil pressure:

 Minimum at idle: 49 kPa (0,5 kgf/cm

2

- 7psi).

 Normal at 3000 rpm: between 147 and 490 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).

3.1.12 Cooling liquid

The engine is cooled by cooling liquid. Use only long-life type
G12+ cooling liquid in order to minimize maintenance. The

capacity of the engine’s cooling system is approximately 3.5

litres. The capacities of the radiator and piping have to be taken
into account as well.

Initially, the engine can be filled 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 tank.
When the engine is on temperature the liquid will expand and
the redundant liquid will be pressed into the expansion tank.
This tank has to be filled up till the mark. The tank has an
overflow connection, which can be used to connect an open
hose to drain the overflow of the cooling liquid to outside the
vehicle.

TECHNICAL INFORMATION

12 W-GV/2, W-GV/3, W-GV/3+, W-GV 8, W-GV 10 and W-GV 15 — June 2017 — EN

3.2 TECHNICAL DATA

3.2.1 Kubota-based models

Genverter Model

Mobile version, dry exhaust

41001120 – genverter
based on Kubota Z482 for
mobile use

41001320 – genverter
based on Kubota D722
for mobile use

41001505 – genverter
based on Kubota D1105
for mobile use

General information

System output

8kVA/6kW

10kVA/8kW

15kVA/12kW

Peak power 200msec

200%

200%

200%

Low rpm setpoint

1800rpm

1800rpm

1500rpm

Max rpm setpoint

3200rpm

3200rpm

3000rpm

Nominal rpm

2500 .. 2800rpm

2500 .. 2800rpm

2000 .. 2600rpm

Sound level @ 7m

54dBA

54dBA

58dBA

Sound level @ 1m

65dBA

65dBA

74dBA

Cooling

Single radiator

Single radiator

Single radiator

Exhaust

Dry type, 1” BSP

Dry type, 1” BSP

Dry type, 1½” BSP

Speed governor

Mechanical

Mechanical

Mechanical

Starter battery capacity

12V / 80Ah

12V / 80Ah

12V / 90Ah

Standard supplies

Digital remote panel (10 m cable), fuel filter, fuel lift pump, user and installation
manuals

Available options

Installation kits, non-earth return (ungrounded), spare part kit, longer or shorter
DDC cables

Mechanical specifications

Dimension (l × b × h)

650 × 545 × 600mm

720 × 545 × 600mm

810 × 565 × 660mm

Dimension mounting (h × w)

340 × 618, 230 × 618mm

340 × 680, 230 × 680mm

340 × 781, 230 × 781mm

Dry weight excl. sound shield

124kg

141kg

187 kg

Dry weight incl. sound shield

154kg

171kg

220 kg

Color

RAL9010 signal white

RAL9020 metallic black

Engine

Engine model

Kubota Z482

Kubota D722

Kubota D1105

Emission Regulation

Tier 4, EPA

Tier 4, EPA

Tier 4, EPA

Engine performance intermittent
SAE J1349

9.32kW @ 3600rpm

14.0kW @ 3600rpm

18.7kW @ 3000rpm

Engine performance continuous
SAE J1349

8.05kW @ 3600rpm

12.15kw @ 3600rpm

16.4kW @ 3000rpm

Number of cylinders

2 3 3

Displacement

0.479 l

0.719 l

1.123 l

Bore & stroke

67 × 68mm

67 × 68mm

78 × 78.4mm

Air intake system

Naturally aspirated

Air consumption

0.95 m3/min

1.22 m3/min

1.46 m3/min

Fuel oil

Diesel fuel oil (ASTM No. 2-D)

Fuel consumption @ full load

275 g/kWh

275 g/kWh

275 g/kWh

Engine cooling

Indirect water cooled

Indirect water cooled

Indirect water cooled

Nominal operation voltage

12VDC

12VDC

12VDC

Alternator

12,5A

40A

40A

Operating principle

Energize to run

Energize to run

Energize to run

Starter power requirement

0.8 kW

0.8 kW

1.0 kW

Monitoring and control

Digitial Diesel Control

Protections

Oil temperature and pressure, coolant temperature

Local control

Start/stop & maintenance

Service interval oil change

200 h

Oil capacity

Approx. 2.5 l

Approx. 3.8 l

Approx. 5.1 l

Lubricant

At least CF

TECHNICAL INFORMATION

W-GV/2, W-GV/3, W-GV/3+, W-GV 8, W-GV 10 and W-GV 15 — June 2017 — EN 13

Alternator

Type

Permanent Magnet Alternator PM

Model

HV/SAE5,
300VAC, 400Hz, 15A

HV/SAE5,
300VAC, 400Hz, 15A

HV/SAE5,
450VAC, 400Hz, 40A

Output voltage per phase (Delta),
no load @ 25˚C

118V @ 1800rpm
236V @ 3600rpm

118V @ 1800rpm
236V @ 3600rpm

240V @ 1800rpm
450V @ 3000rpm

Output frequency

240Hz @ 1800rpm
480Hz @ 3600rpm

240Hz @ 1800rpm
480Hz @ 3600rpm

240Hz @ 1800rpm
400Hz @ 3000rpm

Nominal power (torque)

40 Nm

40 Nm

60 Nm

Configuration

3-phase, Star (for WP-PMG) or Delta (for DC PowerCube)

Nominal efficiency

94%

Cooling

Radiator cooling

Nominal coolant temperature

40 .. 80˚C

Bearing, coupling

Single end bearing, flex plate

Rotor concept

Inner rotor type

Number of phases

3-phase

Insulation class

H

Maximum allowed winding temperature

175˚C

High voltage test

3000V

Regulations and Directives

CE conformity

EMC directive

EMC 2004/108/EC

Emission

EN 55022 (Class A/B household/light industrial use)

Harmonics

EN 61000-3-2 (<16A, Class A)

Dips, variations, flicker

EN 61000-4-11, EN6100-3-3 (designed to meet)

Immunity

EN 61000-6-2, marine suitable or better

LV directive

LVD 2006/95/EC

Safety

EN 60950 Safety of information technology equipment

EN 60335-1 Safety of household and similar electrical appliances, Part 1

EN 60335-2-29 Household and similar electrical appliances – Safety - Particular
requirements for battery chargers

Vibration and shock levels (designed to
meet)

EN 68-2-6, 5-50Hz velocity, max. 20mm amplitude, suitable for marine and
mobile high vibration environments

E-marking (designed to meet)

Automotive EMC 2004/104/EC

EN (designed to meet)

EN 60945

ABYC (designed to meet)

American Boat & Yacht Council

UL or CSA (designed to meet)

UL 458

TECHNICAL INFORMATION

14 W-GV/2, W-GV/3, W-GV/3+, W-GV 8, W-GV 10 and W-GV 15 — June 2017 — EN

3.2.2 Mitsubishi-based models

Genverter Model

Mobile version, dry exhaust

41001220– 2-cylinder genverter based
on Mitsubishi L2E for mobile use

41001420 – 3-cylinder genverter based on
Mitsubishi L3E for mobile use

General information

System output

10kW/8kVA

10kW/8kVA

Peak power 200msec

200%

200%

Low rpm setpoint

1800rpm

1800rpm

Max rpm setpoint

3200rpm

3200rpm

Nominal rpm

2500 .. 2800rpm

2500 .. 2800rpm

Sound level @ 7m

54dBA

55dBA

Sound level @ 1m

65dBA

65dBA

Cooling

Single radiator

Single radiator

Exhaust

Dry type, 1”OT

Dry type, 1”OT

Speed governor

Mechanical

Mechanical

Starter battery capacity

12V / 80Ah

12V / 80Ah

Standard supplies

Digital remote panel (10 m cable), fuel filter, fuel lift pump, user and installation
manuals

Available options

Installation kits, non-earth return (ungrounded), spare part kit, longer or shorter DDC
cables

Mechanical specifications

Dimension (l × b × h)

650 × 545 × 600mm

720 × 545 × 600mm

Dimension mounting (h × w)

340 × 618, 230 × 618mm

340 × 680, 230 × 680mm

Dry weight excl. sound shield

132kg

149kg

Dry weight incl. sound shield

162kg

179kg

Color

RAL9010 signal white
RAL9020 metallic black

RAL9010 signal white
RAL9020 metallic black

Engine

Engine model

Mitsubishi L2E

Mitsubishi L3E

Emission Regulation

Tier 4, EPA

Tier 4, EPA

Engine performance intermittent
SAEJ1995

11.3kW @ 3600rpm

9.4kW @ 3000rpm

16.9kW @ 3600rpm

14.7kW @ 3000rpm

Engine performance continuous
@ 25°C ambient temperature

9.9kW @ 3600rpm

8.5kW @ 3000rpm

15.2kw @ 3600rpm

13.2kW @ 3000rpm

Number of cylinders

2

3

Displacement

0.635 l

0.952 l

Bore & stroke

76 × 70mm

76 × 70mm

Air intake system

Naturally aspirated

Naturally aspirated

Air consumption

1.22 m3/min

1.34 m3/min

Fuel oil

Diesel fuel oil (ASTM No. 2-D)

Diesel fuel oil (ASTM No. 2-D)

Fuel consumption @ full load

297 g/kWh

297 g/kWh

Engine cooling

Indirect water cooled

Indirect water cooled

Nominal operation voltage

12VDC

12VDC

Alternator

40A

40A

Operating principle

Energize to run

Energize to run

Starter power requirement

0.8 kW

0.8 kW

Monitoring and control

Digitial Diesel Control

Digitial Diesel Control

Protections

Oil temperature and pressure, coolant
temperature

Oil temperature and pressure, coolant
temperature

Local control

Start/stop & maintenance

Start/stop & maintenance

Service interval oil change

200 h

200 h

Oil capacity

Approx. 2.9 l

Approx. 4.1 l

Lubricant

At least CF

At least CF

Alternator

Type

Permanent Magnet Alternator PM

Model

HV/SAE5, Delta, 300VAC, 400Hz, 15A

Output voltage per phase (Delta),
no load @ 25˚C

98V @ 1500rpm
196V @ 3000rpm

Output frequency

200Hz @ 1500rpm
400Hz @ 3000rpm

Configuration

3-phase, Star (for WP-PMG) or Delta (for DC PowerCube)

Nominal power (torque)

40 Nm

TECHNICAL INFORMATION

W-GV/2, W-GV/3, W-GV/3+, W-GV 8, W-GV 10 and W-GV 15 — June 2017 — EN 15

Nominal efficiency

94%

Cooling

Radiator cooling

Nominal coolant temperature

40 .. 80˚C

Bearing, coupling

Single end bearing, flex plate

Rotor concept

Inner rotor type

Number of phases

3-phase

Insulation class

H

Maximum allowed winding temperature

175˚C

High voltage test

3000V

Regulations and Directives

CE conformity

EMC directive

EMC 2004/108/EC

Emission

EN 55022 (Class A/B household/light industrial use)

Harmonics

EN 61000-3-2 (<16A, Class A)

Dips, variations, flicker

EN 61000-4-11, EN6100-3-3 (designed to meet)

Immunity

EN 61000-6-2, marine suitable or better

LV directive

LVD 2006/95/EC

Safety

EN 60950 Safety of information technology equipment

EN 60335-1 Safety of household and similar electrical appliances, Part 1

EN 60335-2-29 Household and similar electrical appliances – Safety - Particular
requirements for battery chargers

Vibration and shock levels (designed to
meet)

EN 68-2-6, 5-50Hz velocity, max. 20mm amplitude, suitable for marine and mobile high
vibration environments

E-marking (designed to meet)

Automotive EMC 2004/104/EC

EN (designed to meet)

EN 60945

ABYC (designed to meet)

American Boat & Yacht Council

UL or CSA (designed to meet)

UL 458

OPERATION

16 W-GV/2, W-GV/3, W-GV/3+, W-GV 8, W-GV 10 and W-GV 15 — June 2017 — EN

4 OPERATION

4.1 GENERAL

The genverter is operational after full installation and filling up
with fuel, engine lubricating oil and cooling liquid, connecting
the battery and connecting the digital remote control panel.

4.2 PROGRAMMABLE SPEED

At the time of commissioning, the engine rpm are set to meet
the output requirements of the installation.

4.3 OPERATING INSTRUCTIONS

4.3.1 Daily check of oil level

Be sure to keep the oil level between upper and lower limits of
the oil gauge. Too much oil may cause a drop in output or
excessive blow-by gas, while too little oil may seize the engine's
rotating and sliding parts.

Procedure:

1 Check the engine oil level before starting or more than 5

minutes after stopping the engine.

2 Remove the oil dipstick, wipe it clean and reinsert it.

Take the dipstick out again, check the oil level gauge and
reinsert the dipstick.

Figure 9: Oil dipstick (similar on all models)

3 If the oil level is too low, remove the oil filler plug, and add

new oil to the prescribed level.

4 After adding oil, allow the oil to come down to the oil pan

before checking the oil level again.

4.3.2 Summarized operating instructions (daily use)

Routine "pre-start" checks:

1 Check oil level and cooling liquid level.
2 For systems incorporating PMG: power source selector

switch (off/shore power/generator power) in “off”

position, or switch of all consumers in the usual way. If a
Whisper Switch of Transfer System Switch is installed, this
operates automatically.

3 Switch on battery switch (if installed).
4 Fuel valve: open.

Starting:

Push the start button and hold for a second to initiate the fully
automatic starting procedure.

In operation checks:

1 Check for abnormal noise or vibration
2 Check the output parameters on the remote control

display

3 For systems incorporating PMG: switch power source

selector to “generator” position. If a Whisper Switch of

Transfer System Switch is installed, this operates
automatically.

4 Before loading the generating set up to its maximum, have

it run warm. Continuous load should be restricted to 70 %
of maximum load.

Stopping the genverter:

1 If the genverter 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 around 5 min.

2 Press the STOP button.
3 Switch to another AC power source, if available

4.3.3 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 installation.
2 Check if the installation conforms to the installation

instructions.

3 Ensure the engine is free to turn without obstruction.
4 Check all hoses and hose connections for leaks.
5 Check all cables and terminal connections.

Routine "pre-start" checks:

1 Check engine oil level. The genverter switches off in the

event of insufficient oil pressure. Even when the oil level is
too low, the oil pressure can be high enough not to trip an
alarm. Do not run the engine with the oil below the lowest
mark, because a smaller volume of oil will become
contaminated considerably quicker than a larger volume.
Moreover, a low level may affect cooling. 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 for leakages.
3 Switch off all devices.
4 Switch on the battery switch (when installed).

Starting the genverter:

By pushing the start button and holding it for a second, the
electric system is activated. You can monitor the
procedure on the display of the remote control panel.
First, the fuel pump will prime the fuel for a few seconds

OPERATION

W-GV/2, W-GV/3, W-GV/3+, W-GV 8, W-GV 10 and W-GV 15 — June 2017 — EN 17

(settable); the starter will then crank the engine until it
starts. While starting the alarms are blocked (this is
achieved by pushing the Start/Stop button). The alarms are
reactivated after 10 seconds.

Warm up the engine without load for 3 minutes. A restart
protection prevents cranking the engine when it is already
running, which could cause damage.

Never use ether or gasoline to facilitate a cold
start as it could damage the engine.

Checks once the engine is in operation:

1 Check for abnormal noise or vibration.
2 Check the output parameters on the remote control

display.

3 Observe the exhaust at the rated load.

The exhaust must be free from soot. Do not allow the
engine to run with visible smoke from the exhaust without
investigating the cause, as this may result in an expensive
breakdown.

Engine load during longer operation:

During the first 50 hours of running, the continuous load
should be restricted to 70 % of the maximum load.
Running at no load or light load for long periods in the first
50 hours may cause cylinder glazing and high oil
consumption.

Avoid overloading the genverter. Overloading occurs when
the electrical load (demand) is so high that by the diesel
engine has trouble driving the alternator. It causes the
engine to run rough, while using oil and excessive fuel and
producing soot. The engine may even stop. The genverter
should therefore 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 genverter’s life expectancy, the

nominal electrical demand of the system should not

exceed 70% or the genverter’s rated maximum load.

Please note this when switching on your electrical
equipment! Nevertheless, the genverter is designed so as
not to overheat, even under extreme conditions.

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

Neither remove the battery while the engine is
running nor remove any electrical cable while the
battery is connected to the circuit. Only
disconnect the battery with the engine stopped
and all switches in "OFF" position.

Stopping the genverter:

1 Avoid stopping the genverter abruptly after a long period

of operation at high load. Prior to switching off the
genverter, decrease the load (i.e. turn off most electrical
consumers) and let the genverter run at low load for
approx. 5 minutes to allow the engine to cool down
sufficiently. Another reason to switch off electrical
consumers prior to stopping the genverter is the voltage
drop that occurs as the engine comes to a halt.

If the genverter is operating in a hot environment and is
not allowed to cool down, excessive heat in the engine
may trip the "high temperature" alarms. This will prevent
restarting of the engine for some time.

2 Press the STOP button.
3 Switch to another 230V power source, if available.

If the engine is not running and the ‘failure’ and
‘charging’ LEDs are blinking, press the stop

button in order to prevent the starter battery
from being drained.

MAINTENANCE

18 W-GV/2, W-GV/3, W-GV/3+, W-GV 8, W-GV 10 and W-GV 15 — June 2017 — EN

5 MAINTENANCE

5.1 MAINTENANCE INTERVALS

Service level

break-in 1 2 3 4

before

each
start

after

35-50 h

every

200 h/

6M*

every

400 h/

12M*

every

800 h/

24M*

every

1600 h/

36M*

Lubricating oil

check oil level



change oil and oil filter cartridge



 (12M)

check lubricating oil pressure



Cooling
system

check cooling liquid level



check and clean radiator

 check hoses



check cooling system

/

Exhaust

check exhaust

 Nuts & bolts

check all and tighten where necessary



Electrics

check all electrical connections





check/adjust V-belt tension



check battery (acid level, connections)



Fuel system

drain water from tank



replace fuel filter

 check fuel hoses



check injection nozzles and injection pressure

 check injection pump

 (3200h)

Air supply

check air strainer and filter element



Cylinder head

Retighten cylinder head bolts and readjust valve
clearance

/

* Whichever comes first.
 Can be done by user. Corrective action to be taken whenever necessary.
 WhisperPower service centre to be contacted.

5.2 ALTERNATOR

The alternator does not require maintenance.

5.3 ENGINE

5.3.1 Preliminary instructions

The first service on the engine should be carried out after 50
running hours. This period also applies after a major overhaul.
During 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
consumption.

 For the same reason it is of the greatest importance to use

the right oil specification.

5.3.2 Bleeding the fuel lines

When the engine is started up for the first time or after it has
run out of fuel, the fuel system may need to be primed. Push
the start button activating the electric system and activating the
fuel pump. When more time is needed to bleed, hold the

“Start/Stop” button on the local control panel (so not on the

remote panel). While the button is held, the pump will work,
but the unit will not start. Hold as long as necessary to bleed
the system

5.4 REGULAR MAINTENANCE

5.4.1 General precautions

All regular maintenance can be carried out when the enclosure
is open. When oil and dirt have gathered in the enclosure,
measures have to be taken to prevent oil from being spilled.

MAINTENANCE

W-GV/2, W-GV/3, W-GV/3+, W-GV 8, W-GV 10 and W-GV 15 — June 2017 — EN 19

CAUTION!
Risk of personal injury, fire and/or electric shock

 Be sure to conduct daily checks, periodic maintenance,

refuelling or cleaning on a level surface with the engine
shut off and the control system fuse removed.

 Do not touch muffler or exhaust pipes while they are hot;

Severe burns could result.

 Allow the engine to cool down sufficiently, especially

before changing the oil or the oil filter cartridge. Oil can be
hot and cause burns.

 Contact with engine oil can damage your skin. Put on

gloves when using engine oil. If you come in contact with
engine oil, wash it off immediately.

 When changing engine oil, dispose it according to local

regulations.

 When cleaning any parts, do not use gasoline but use

regular cleanser.

 Always use proper tools, that are in good condition. Make

sure you understand how to use them, before performing
any service work.

 Be sure to tighten all bolts lest they should be loose.

Tighten the bolts by the specified torque.

 Do not put any tools on the battery, or battery terminals

may short out. Severe burns or fire could result. Detach
the battery from the engine before maintenance.

5.4.2 Servicing after break-in

 Change engine oil and replace the oil filter (refer to 5.4.3).
 Check and tighten nuts, bolts, and unions, paying

particular attention to the fuel system and using the
torque chart below.

Standard torque chart

Size

M6x1.0

M8x1.25

M10x1.5

Nm*

10.8+1.0

25.5+2.9

49.0+4.9

* Apply 80% torque when tightening bolts to
aluminium alloy.

 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. When ramping up
RPM the engine will probably produce some smoke. After
stabilizing on the right RPM for the load the exhaust
should be free from soot.

 Check the electrical connections.

5.4.3 Changing engine oil and oil filter cartridge

1 Run the engine until it is on temperature, stop it and let it

cool down sufficiently to allow safe working.

2 Drain oil through the dipstick hole using a vacuum pump as

commonly used in garages.

3 Put some tissues under the oil filter cartridge.
4 Remove the old cartridge with a filter wrench.
5 Apply a film of oil to the gasket for the new cartridge.
6 Screw in the cartridge by hand. When the gasket contacts

the seal surface, tighten the cartridge not too firmly, by
hand.

7 Remove the oil filler cap on top of the engine, refill the

engine with oil (refer to 3.1.11 for specifications and
quantity). Allow the oil to come down to the oil pan and
check the oil level.

8 The oil level should be as close as possible to the maximum

level. Add (or drain) oil as necessary.

NOTE: When the genverter runs less than 200 hours a year, the
oil should be changed yearly.

5.4.4 Checking the battery

 Check battery terminals for corrosion
 Check the battery acid level (not applicable when sealed

batteries are used).

5.4.5 Adjusting the V-belt tension

Before adjusting belt tension, inspect the belt for glazing,
cracks, or dryness. A worn or damaged belt should be replaced.

1 Apply moderate thumb pressure to the belt between the

pulleys. When the belt is pressed in the middle of the span,
the deflection should be between 7 mm and 9 mm.

2 If the tension is incorrect, loosen the alternator mounting

bolts and, using a lever placed between the alternator and
the engine block, pull the alternator out until the
deflection of the belt falls within acceptable limits, then
tighten the alternator mounting bolts.

(1) Alternator belt (A) 7 mm to 9 mm under a load of 10 kgf
(2) Bolt and nut

Figure 10: Alternator belt (similar on all models)

2

1

A

MAINTENANCE

20 W-GV/2, W-GV/3, W-GV/3+, W-GV 8, W-GV 10 and W-GV 15 — June 2017 — EN

5.4.6 Draining water from the fuel tank

NOTE:

This procedure is unusual on mobile installations.
It is included for completeness.

When handling fuel, make sure there are no open
flames or other fire hazards near the engine.
Wipe off any spilled fuel completely. Spilled fuel
can ignite and cause fire.

If fuel gets mixed with particles of foreign matter such as dust,
dirt, or water, it can cause not only a decrease of output but
also malfunctions of the fuel system. To avoid such problems,
drain fuel tank as described below.

1. Position an oil pan (capacity of 2 litres or more) under the

drain cock of fuel tank.

2. Open the drain cock of fuel tank and drain at least 1 or 2

litres of fuel.

3. Make sure that all water and particles of foreign matter

are discharged with the fuel. Close the drain cock.

Figure 11 : Draining water from fuel tank

5.4.7 Replacing the fuel filter

Filter change depends on the level of contamination of the fuel,
but should be done at least every 400 running hours. A clogged
filter results in a lack of output of the engine and irregular
running. Before changing the filter, clamp off the supply line.
The arrow on the filter housings indicates the flow direction.
Remove the hoses from the old filter and fit the new filter.

Figure 12: Fuel filter (similar on all models)

5.4.8 Changing the air filter element

The genverter is standard supplied with an air inlet filter
element. Filter change depends on air quality.

Procedure:

1. Unscrew the cover in order to gain access to the filter.

2. Clean the foam around the element with compressed air

and clean the strainer element.

3. Check the air filter and replace it when necessary (do not

clean the air filter element).

4. Put back the cover and retighten the screws.

5.4.9 Checking hoses and electrical connections

Visually check cooling hoses, fuel hoses and electrical wiring,
paying particular attention to abrasion, wear and corrosion.
Have items replaced when necessary.

5.4.10 Servicing after 800 hours and beyond

This includes the items described above, but also procedures
requiring a professional diesel mechanic. Contact your
WhisperPower Service Centre. Please find some essential data
for Kubota-based genverters below:

‒ Valve clearance: from 0.145 mm to 0.185 mm when the

engine is cold.

‒ Rocker arm bracket nut M6 × 1: from 9.81 nm to 11.2 Nm
‒ Cylinder head screw M8 × 1.25: from 38 Nm to 42 Nm.

5.5 PUTTING OUT OF SERVICE

When not using the genverter for a longer period it is
recommended to perform 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.

3. Run the engine until it is on temperature, stop it and let it

cool down sufficiently to allow safe working.

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

5. Disconnect the battery and store it in a dry place free of

frost and charge it regularly.

6. Close inlet and outlet openings with tape.

7. Protect the genverter against the influences of bad

weather conditions.

This method of preservation will be sufficient for 6 months.
Change oil before using the engine again.

TROUBLESHOOTING

W-GV/2, W-GV/3, W-GV/3+, W-GV 8, W-GV 10 and W-GV 15 — June 2017 — EN 21

6 TROUBLESHOOTING

6.1 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.

If during these measurements the engine immediately stops
after starting and an error code is displayed at the remote

control panel ( “AC VOLTAGE”), the Genverter can be restarted

by means of a “service start” in the service menu (see “service
start” in the user’s manual of the Digital Diesel Control). Started

this way, the Genverter will keep running for 2 minutes before
it stops. This offers you the possibility to carry out
measurements to investigate the cause of the failure. This
procedure should only be carried out by an experienced
electrician.

6.1.1 Failure codes

A failure code is displayed when a failure at the Genverter is
detected. A warning code is displayed when a parameter
deviates from the setting.

6.2 ALTERNATOR/ ELECTRICAL FAULTS

Beware of parts which are live! The alternator
generates voltage up to 650 V.

Remove 3 A fuse from the control panel while
working on the Genverter in order to prevent the
engine from starting.

Warning code

Problem

NO WARNING

None (no warning was detected)

LOW STARTBAT

Voltage of the start battery (BAT1) is below setting

NO BAT2

No second battery detected or voltage is below 5V while nominal voltage is set at 12V or 24V check
connections/ fuses/ polarity of the second battery)

LOW BAT2

Voltage of the second battery (BAT2) is below setting

COMMUNICATION

Communication error between the panel and the Genverter. Check the cable connection between the
panel and the control unit.

OIL PRESS HIGH

The pressure switch in the cooling system indicates a too high oil pressure

OIL PRESSURE

The oil pressure in the lubrication system is too low

ENGINE TEMP

Temperature engine oil temperature is too high

Failure code

Problem

NO FAILURE

None (no failure was detected)

COMMUNICATION

Communication error between the panel and the Genverter

LOW BAT1

Starter battery voltage (BAT1) too low

PM ALTERNATOR

PM alternator voltage is not OK

OIL TEMP

Oil temperature too high

OIL PRESSURE

Oil pressure failure (lubricating oil pressure too low)

SOFTWARE INV

Software failure in inverter

COMM ERROR INV

Communication between inverter and interface lost

FAILURE TO START

No start signal

TROUBLESHOOTING

22 W-GV/2, W-GV/3, W-GV/3+, W-GV 8, W-GV 10 and W-GV 15 — June 2017 — EN

6.2.1 Troubleshooting table for alternator

PROBLEM

CAUSE

SOLUTION

No output (voltage) at all

 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

 Alternator failure

Contact WhisperPower Service

Genverter output voltage too low
when no load is on it and RPM is
above 2500 RPM

 Alternator failure

Contact WhisperPower Service

Genverter output voltage too low
under load, but OK in no load
condition

 Genverter is overloaded

Switch off a load; reduce number of consumers

 Insufficient engine RPM

Increase minimum RPM setting

 Engine RPM drops when loaded

Refer to “Engine speed drops” section in 6.2

6.2 ENGINE FAULTS

Remove 3 A fuse from the control panel while
working on the Genverter in order to prevent the
engine from starting.

6.2.1 General

When the engine is not cranking well, starting problems almost
always originate from battery problems or poor battery cable
connections.

When the engine does crank, 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 engine is
detected.

6.2.2 Troubleshooting table for engine

PROBLEM

CAUSE

SOLUTION

Diesel engine fails to crank; no
response at all

 Faulty fuse on the control panel

Replace fuse

 Battery switch off

Switch on

 Battery completely empty

Charge or replace battery

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

 Almost certainly this is a battery

problem. Display will indicate “LOW

BAT1”

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

 Wiring 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

 Engine lubricating oil too thick

Change oil, using a lower viscosity grade

Starter is turning engine smoothly,
but engine fails to start

 Out of fuel or faulty fuel, water in the

fuel

Fill up with fuel or replace with better quality

 Fuel solenoid is not opening (no “click”

can be heard)

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

 Fuel lift pump is not working

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

 Air in fuel lines

Bleed air from fuel system (refer to maintenance
section)

TROUBLESHOOTING

W-GV/2, W-GV/3, W-GV/3+, W-GV 8, W-GV 10 and W-GV 15 — June 2017 — EN 23

PROBLEM

CAUSE

SOLUTION

 Blocked injector

Have the injector tested and cleaned if necessary

 Wrong valve clearance

Adjust valve clearance

 Low compression because of dirty valves

Contact WhisperPower service department for
advice

 Loss of compression by wear out or

damage

Repair by WhisperPower service

Starter is turning engine smoothly,
but engine runs irregularly after
starting

 Faulty glow plug

Replace faulty glow plug. Consider replacing both
or all three taking into account the number of
starts completed.

Engine runs irregularly

 Unsuitable or contaminated fuel
 Lack of fuel

Fill up with fuel or replace by better quality

 Air in the fuel pipes

Bleed air from fuel system (refer to maintenance
section)

 Choked fuel filter

Check fuel filter and replace if necessary

 Disturbances on the electrical system/

user side

Check if electrical load is fluctuating

 Faulty fuel lift pump

Check and repair or replace

 Choked air filter
 Lack of air

Check the air intake

 Choked exhaust system, exhaust blocked

Check the exhaust piping, inspect inside of
manifold

 Faulty actuator

Replace faulty parts. Contact WhisperPower
service department for advice.

 Blocked injector

Have the injector tested and cleaned if necessary

 Wrong valve clearance

Adjust valve clearance

 Lack of fuel

Check fuel supply system: fuel pump and filter

Engine speed drops

 Genverter overloaded

Reduce the electrical load (switch off some
consumers)

 Fuel problem

Check fuel supply and clean fuel filter

 Too much oil.

Drain oil to proper level

 Lack of intake air.

Check air intake; clean air filter

 Choked exhaust system, exhaust blocked.

Check the exhaust piping; inspect inside of
manifold

 Faulty actuator

Contact WhisperPower service department for
advice

 Defective alternator (windings or other)

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

 Damaged engine

Repair by WhisperPower service

Engine does not stop on command

 Fuel solenoid is not switching off
 Loss of control

Faulty Digital Diesel Control unit. Stop the engine
manually using 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: oil level too high, worn cylinder,
stuck, broken or worn piston rings.

Check the oil level
Check the compression

 When the engine RPM is ramping up to

react at a load step some smoke may be
unavoidable.

 Wrong setting of minimum RPM.
 Sooty black smoke –incomplete

combustion caused by: overload, choked
air filter, air inlet temperature too high,
unsuitable fuel or water in fuel.

 Valve clearance incorrect.

No action required.

Readjust minimum rpm setting
Check the fuel.
Check for overload
Check the air filter
Adjust minimal RPM setting
Readjust valve clearance

TROUBLESHOOTING

24 W-GV/2, W-GV/3, W-GV/3+, W-GV 8, W-GV 10 and W-GV 15 — June 2017 — EN

PROBLEM

CAUSE

SOLUTION

 Continuous running with very low load.

Increase load and have the engine run for a few
hours

Engine starts, but stops after 10 up
to 30 seconds

 Protection system stops the engine; this

can be caused by oil pressure failure,
loose wire or faulty alarm switch. Digital
Diesel Control will help to indicate
failure.

 Faulty alarm switch/sensor

Refer to Chapter 3 and page 24 and the DDC
operating manual for information on the alarm
system. Bypassing a switch can help to confirm the
failure. But be aware: running with a by-passed
alarm switch can cause damage!
Replace the switch. By-passing the switch makes it
possible to keep running. But be aware: running
with a by-passed alarm switch can cause damage!

Engine stops by itself

 Overload or short circuit

Switch off the consumers and test for short circuit.

 Lack of fuel

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

 Coolant temperature too high (>105°C)

Check cooling system

 Oil pressure low (oil pressure switch

tripped)

Check oil level
Check oil pressure and have engine repaired by
WhisperPower if necessary.

 Air or water in the fuel.
 Blocked air or fuel filter.

Check and clean

 Loss of compression by wear out or

damage.

Repair by WhisperPower service.

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 using the exact values,
taking into account the power factor of the
consumers. When in doubt, measure the power
directly using an appropriate instrument.

 Oil level too high

Drain oil to the correct level

 Choked fuel 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 injector checked

 Loss of compression, sticking or damaged

piston ring

Have the compression measured
Clean or replace the rings

 Wear out of cylinder

Have the compression measured and have the
engine overhauled

Over-temperature

 Overload.

Reduce the load

 Radiator choked by dirt
 Hot air circulation in the radiator.

Clean radiator

 Exhaust choked with carbon
 Cooling circuit failure

Clean exhaust
Contact WhisperPower service

TROUBLESHOOTING

W-GV/2, W-GV/3, W-GV/3+, W-GV 8, W-GV 10 and W-GV 15 — June 2017 — EN 25

6.2.3 Warnings

Genverter must be shut off immediately if:

 Unusual noise comes from Genverter.
 Exhaust gases suddenly colour dark.
 Engine failure warning light is on.

6.2.4 Service address

If you cannot correct a problem with the aid of the
troubleshooting tables, contact your WhisperPower Service
Centre or WhisperPower Netherlands for an extended service
list.

Phone: INT [phone].

SPARE PARTS

26 W-GV/2, W-GV/3, W-GV/3+, W-GV 8, W-GV 10 and W-GV 15 — June 2017 — EN

7 SPARE PARTS

We recommend the following spares for service and maintenance.

article no.

• Kit A: parts for regular maintenance (marked *)

40401760 (Kubota Z482 and D722)
40401863 (Kubota D1105)
40401860 (Mitsubishi L2E and L3E)

• Kit B: parts for maintenance + spare parts (marked *+**)

40401761 (Kubota Z482 and D722)
40401864 (Kubota D1105)
40401861 (Mitsubishi L2E and L3E)

Refer to the WhisperPower website for an overview of the spare parts kits’ contents.

DESCRIPTION

GV/2 K, GV 8
(Kubota Z482)

GV/3 K, GV 10
(Kubota D722)

GV/3+, GV 15
(Kubota D1105)

GV/2 M, GV 8
(Mitsubishi L2E)

GV/3 M, GV 10
(Mitsubishi L3E)

Fuel filter (*)

40209030

40209030

40209030

40209030

40209030

Fuel lift pump 12V

50201160

50201160

50201160

50201160

50201160

V-belt (*)

40403120

40403120

40405120

50203120

50203120

Oil filter (*)

40403121

40403121

40405121

40203121

40203121

Air filter

40230007

40230007

50230007

40230007

40230007

WPL Oil 4 Ltr.

40222204

40222204

40222204

40222204

40222204

WPL Coolant 4 Ltr.

40222214

40222214

40222214

40222214

40222214

Water pump complete

40401870

40401870

40201670

40201870

40201870

Impeller + gasket / O-ring (*)

40209011

40209011

40209011

40209011

Pump repair kit A

40201471

40201471

40201273

40201471

40201471

Pump repair kit B (**)

40201472

40201472

40201274

40201472

40201472

Local control panel PCB

50209142

50209142

50209142

50209142

50209142

Electronic Whisper Control Unit

40401150

40401150

40401150

40401150

40401150

Fuses 10 Amps (*)

50212170

50212170

50212170

50212170

50212170

Fuses 3 Amps (*)

50212154

50212154

50212154

50212154

50212154

Wiring loom complete

40401886

40401886

40401886

40401886

Digital Diesel Remote control panel

40209102

40209102

40209102

40209102

40209102

DDC Cable remote control 15 mtr.

50209133

50209133

50209133

50209133

50209133

Lube oil pressure switch

50209212

50209212

50209212

50209212

50209212

Exhaust temperature switch

50209238

50209238

50209238

50209238

50209238

Coolant temperature switch

50209208

50209208

50209208

50209208

50209208

DC Power Cables Red / Black

50201245

50201245

50201245

50201245

50201245

Overhaul gasket kit / Seal kit

40403133

40404133

40405133

50203033

50204033

Cylinder head gasket kit

40403130

40404130

40405130

50203030

50204030

Glow plug

40403140

40403140

40201640

50203040

50203040

Injector nozzle (**)

40403150

40403150

40201650

50203050

50203050

Fuel pump (high pressure) complete

40403160

40404160

40201680

50203160

50204160

Thermostat (**)

40403145

40403145

40403145

50203045

50203045

Thermostat gasket (**)

40403138

40403138

40403138

50203038

50203038

Rocker cover gasket (**)

40403137

40404137

40201637

50203037

50204037

WHISPERPOWER PRODUCTS

W-GV/2, W-GV/3, W-GV/3+, W-GV 8, W-GV 10 and W-GV 15 — June 2017 — EN 27

8 OTHER PRODUCTS FROM WHISPERPOWER

WhisperPower offers a wide range of power-related products. In our PowerBook, these are arranged as follows.

Power Generation

• Diesel generators - Genverter

• Diesel generators - 3000 rpm

• Diesel generators - 1500 rpm

• Installation kits

• AC and DC belt driven generators

Power Conversion

• Sinewave inverters

• Inverter/chargers

• Battery chargers

• Monitoring and control

Power Storage

• AGM and gel batteries

• Lithium-ion batteries

• Battery-related products

• Solar energy

Power Distribution

• Shore power connect

• AC distribution

• Electrolysis prevention

• DC distribution

Hybrid power systems for power
generation & propulsion

• 24/ 48VDC based systems up to 15kW

• systems up to 300kW for super yachts

For instant and detailed information, we recommend checking our website: www.whisperpower.com.

MAINTENANCE LOG

28 W-GV/2, W-GV/3, W-GV/3+, W-GV 8, W-GV 10 and W-GV 15 — June 2017 — EN

Maintenance log

Wartungslogbuch

Journal de maintenance

This log must remain with the generator. In the
event of a warranty claim, a copy of this log has to
be sent to the manufacturer.

Dieses Logbuch verbleibt an Bord. Im Falle eines
Garantieanspruchs muss eine Kopie an den
Hersteller geschickt werden.

Ce journal demeure à bord. En cas de prétention
à garantie, une copie est à dresser au fabricant.

Inspection required at:

Vorgesehen bei:

Inspection exigée après:

Service level:

Inspektionskategorie:

Catégorie d'inspection:

Hours on indicator :

Stand Betriebsstundenzähler :

Etat du compteur d'heures:

Inspected by:

Prüfer:

Contrôleur:

Date:

Datum:

*) Seal, stamp & full address of responsible WhisperPower
Service Center (only applicable to items marked )

*) Stempel bzw. volle Adresse der Whisperpower
Servicefirma (nur für mit  markierten Servicearbeiten)

*) Cachet et adresse complète du centre de services
WhisperPower (seulement pour les travaux marqués ).

01

35 - 50 h

break-in

02

200 h

1

03

400 h

1,2

04

600 h

1

05

800 h

1,2,3

*)

06

1000 h

1

07

1200 h

1,2

08

1400 h

1

09

1600 h

1,2,3,4

*)

10

1800 h

1

11

2000 h

1,2

12

2200 h

1

13

2400 h

1,2,3

*)

14

2600

1

15

2800 h

1,2

16

3000 h

1

13

3200 h

1,2,3,4

*)

14

3400 h

1

15

3600 h

1,2

16

3800 h

1

17

4000 h

1,2,3

*)

18

4200 h

1

MAINTENANCE LOG

W-GV/2, W-GV/3, W-GV/3+, W-GV 8, W-GV 10 and W-GV 15 — June 2017 — EN 29

Inspection required at:

Vorgesehen bei:

Inspection exigée après:

Service level:

Inspektionskategorie:

Catégorie d'inspection:

Hours on indicator :

Stand Betriebsstundenzähler :

Etat du compteur d'heures:

Inspected by:

Prüfer:

Contrôleur:

Date:

Datum:

*) Seal, stamp & full address of responsible WhisperPower
Service Center (only applicable to items marked )

*) Stempel bzw. volle Adresse der Whisperpower
Servicefirma (nur für mit  markierten Servicearbeiten)

*) Cachet et adresse complète du centre de services
WhisperPower (seulement pour les travaux marqués ).

19

4400 h

1,2

20

4600 h

1

21

4800 h

1,2,3,4

*)

22

5000 h

1

23

5200 h

1,2

24

5400 h

1

25

5600 h

1,2,3

*)

26

5800 h

1

27

6000 h

1,2

28

6200 h

1

29

6400 h

1,2,3,4

*)

30

6600 h

1

31

6800 h

1,2

32

7000 h

1

33

7200 h

1,2,3

*)

34

7400 h

1

35

7600 h

1,2

36

7800 h

1

37

8000 h

1,2,3,4

*)

38

8200 h

1

39

8400 h

1,2

40

8600 h

1

41

8800 h

1,2,3

*)

42

9000 h

1

MAINTENANCE LOG

30 W-GV/2, W-GV/3, W-GV/3+, W-GV 8, W-GV 10 and W-GV 15 — June 2017 — EN

Supplier's Declaration of Conformity/Incorporation

No. 7015001001

Issuer's name: WhisperPower BV
Issuer's address: Kelvinlaan 82, NL-9207 JB Drachten

Object of the declaration:

WhisperPower two and three cylinder Genverters, model nos. 41001120, 41001220, 41001320, 41001420, 41001520,
41005020, 41007020 and 41009020

all serial nos.

The object of the declaration described above is in conformity with the requirements of the following Directives and standards, as
applicable:

Document

Title

2004/108/EC

EMC Directive

EN 61000-3-2:2006

Electromagnetic compatibility (EMC) - Part 3-2: Limits - Limits for harmonic current emissions

EN61000-6-1: 2007

Electromagnetic compatibility (EMC). Generic standards. Immunity for residential,
commercial and light-industrial environments

EN 61000-6-2: 2007

Electromagnetic compatibility (EMC) - Part 6-2: Generic standards - Immunity for industrial
environments

EN 61000-6-3: 2007+A1:2011

Electromagnetic compatibility (EMC) -- Part 6-3: Generic standards - Emission standard for
residential, commercial and light-industrial environments

2006/95/EC

Low Voltage Directive

EN 60950:2000

Safety of information technology equipment

2004/104/EC

Automotive EMC Directive

2004/26/EC

Non-Road Mobile Machinery Exhaust Emissions Directive

2006/42/EC

Machinery Directive

EN 842:1996+A1:2008

Safety of machinery - Visual danger signals - General requirements, design and testing

ISO 12100:2010

Safety of machinery - General principles for design - Risk assessment and risk reduction

The machinery is incomplete and must not be put into service until the machinery into which it is to be incorporated or the vehicle into
which it is to be installed, has been declared in conformity with the provisions of the Directive.

We undertake to transmit, in response to a reasoned request by the appropriate national authorities, relevant information on the partly
completed machinery identified above.

Signed for and on behalf of:

WhisperPower BV

M. Favot,
Chief Technical Officer,

Drachten, March 2, 2017

The technical documentation for the machinery is available from:
WhisperPower BV, Kelvinlaan 82, 9207 JB Drachten, Netherlands

Kelvinlaan 82, 9207 JB Drachten, Netherlands

Tel : + 31-512-571550 / Fax : + 31-512-571599

www.whisperpower.com / [e-mail]