Mastervolt Whisper 6 User Manual Download Page 2

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November 2004 / WHISPER 6 / 12 Mobile / EN

CONTENTS

This manual applies to the Mastervolt Whisper 6/ 12 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

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

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 6/12 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

DDC electronic control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

2.5.4

Battery charger, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

2.5.5

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

2.5.6

Control

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

2.5.7

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

2.5.8

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

2.5.9

Load indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

2.5.10

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

2.5.11

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

2.5.12

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

2.5.13

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

Summary of Contents for Whisper 6

Page 1: ...g 93 1105 AN Amsterdam The Netherlands Tel 31 20 3422100 Fax 31 20 6971006 www mastervolt com USERS MANUAL FOR MOBILE APPLICATIONS V1 November 2004 WHISPER 6 12 3000 RPM Mobile diesel generating set 2...

Page 2: ...lures 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 12 generating set 8 2 3 1 Features 8 2 3 2 Remote cont...

Page 3: ...4 3 Regular maintenance 25 4 3 1 Maintenance schedule 26 4 3 2 Putting out of service 26 5 TROUBLE SHOOTING 27 5 1 Alternator malfucntions AC trouble 27 5 1 1 General 27 5 1 2 Trouble shooting check l...

Page 4: ...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 d...

Page 5: ...n 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 a...

Page 6: ...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...

Page 7: ...y is closed Never the less take note of the signs on the generating set which shows symbols in a triangle indicating danger When service has to be executed while the engine is running be aware of movi...

Page 8: ...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 w...

Page 9: ...d water cooled 13 Thermo switch alternator 14 Injector 2x W6000 3x W12000 15 Glowplug 2x W6000 3x W12000 16 Valve cover 17 Circulation pump engine cooling 18 Filling cap oil 2x 19 Solenoid 20 Electric...

Page 10: ...t is based on the Mitsubishi L2E 2 cylinder W6 or L3E 3 cylinder W12 diesel engine The engine is indirectly injected The engine is water cooled and the cooling liquid is cooled by a radiator The engin...

Page 11: ...n 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 cha...

Page 12: ...ltage 230V 50 Hz alternating current AC single phase Output rating 50Hz 5 kW 6 10 kW 12 Power factor 1 Voltage tolerance 5 optional voltage regulator 2 Frequency tolerance 5 Optional electronical Gove...

Page 13: ...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 soleno...

Page 14: ...M R E T R A T S G N I R U S E M T N E R R U C R E M R O F S N A R T BLUE 1 7 BLUE GREEN 1 8 0 1 J 7 1 K C A L B E U L B 8 J 2 1 5 1 K C A L B 2 1 J 8 1 K N I P E U L B PURPLE 1 6 4 1 J 6 1 K C A L B...

Page 15: ...G N I R U S E M T N E R R U C R E M R O F S N A R T BLUE 1 7 BLUE GREEN 1 8 0 1 J 7 1 K C A L B E U L B 8 J 2 1 5 1 K C A L B 2 1 J 8 1 K N I P E U L B PURPLE 1 6 4 1 J 6 1 K C A L B E L P R U P 6 1...

Page 16: ...O T O M R E T R A T S G N I R U S E M T N E R R U C R E M R O F S N A R T BLUE 1 7 BLUE GREEN 1 8 0 1 J 7 1 K C A L B E U L B 8 J 2 1 5 1 K C A L B 2 1 J 8 1 K N I P E U L B PURPLE 1 6 4 1 J 6 1 K C A...

Page 17: ...EUTRAL NOT CONNECTED MAIN WINDING BLACK 4 BLACK 4 RED 3 MAIN WINDING GREEN 2 RED 3 EXCITATION GREEN 1 WINDING YELLOW GREEN DDC AC 1 YELLOW GREEN BLUE 33 BROWN 33 BLUE DDC ct 1 11 RED CURRENT TRANSFORM...

Page 18: ...IATORCOOLER RADIATORCOOLER ENGINE FUSE 5A FUSE 5A POWER SUPPLY 230 VAC ENGINE GENERATOR 12VDC 12VDC M M 230VAC 230VAC M M 12VDC 12VDC K1 K1 K2 K2 230VAC 230VAC 230 115VAC 230 115VAC 200VA 200VA TRAFO...

Page 19: ...NAL BLOCK THERMOSTAT COOLER ALTERNATOR BAT FUSE JUCTION BOX AIR FANS FUSE CONTROL PANEL RADIATOR COOLER ALTERNATOR PUMP 2 BAT ENGINE ENGINE M M M M M M M M CU0 75 80 70 C CU4 CU0 75 45 35 C CU0 75 4 1...

Page 20: ...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...

Page 21: ...n 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...

Page 22: ...linder 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 ne...

Page 23: ...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 expen...

Page 24: ...n and put them in a can with preservation diesel fuel Start the engine and run the engine warm 3 Drain the hot engine oil and refill with preservation oil 4 The coolant can stay in the engine and radi...

Page 25: ...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...

Page 26: ...RT BAT Starter battery voltage too low ALTERNATOR No output battery charging voltage AC ALTERN TEMP Alternator temperature is too high WATER TEMP Coolant temperature is too high OIL PRESSURE Oil press...

Page 27: ...ction 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...

Page 28: ...eplace 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 Insuff...

Page 29: ...tery 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...

Page 30: ...screw is to be locked in position with the lock nut 5 4 2 Adjusting valve clearance and retightening the cylinder head bolts Both procedures has to be executed with a cold engine When both procedures...

Page 31: ...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 2 T...

Page 32: ...g of Shaft 13 Bearings 2 pcs 10 O ring 9 Seals 2 pcs 8 Clips 1 set 11 12 O ring 14 50209010 Waterpump repair kit B same as repair kit A excluding the shaft 13 and O ring 14 50201060 Capacitor xx micro...

Page 33: ...r 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 502...

Page 34: ...34 November 2004 WHISPER 6 12 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 12 Mobile November 2004 35 NOTES...

Page 36: ...November 2004 WHISPER 6 12 Mobile EN MASTERVOLT Snijdersbergweg 93 1105 AN Amsterdam The Netherlands Tel 31 20 3422100 Fax 31 20 6971006 www mastervolt com info mastervolt com...

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