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Whisper Power W-GV 4 Scalino, User Manual

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CONTENTS 

W-GV4 Scalino outdoor — April 2017— EN

 

3

 

5.4.5

 

Replacing the fuel filter .................................................................................................................................... 18

 

5.4.6

 

Air filter element .............................................................................................................................................. 18

 

5.4.7

 

Checking hoses and electrical connections ...................................................................................................... 18

 

5.4.8

 

Retightening cylinder head bolts and adjusting valve clearance ..................................................................... 18

 

5.5

 

Putting out of service ......................................................................................................................................................... 19

 

6

 

TROUBLESHOOTING ................................................................................................................................................................. 20

 

6.1

 

General ............................................................................................................................................................................... 20

 

6.2

 

Alternator/ electrical faults ................................................................................................................................................ 20

 

6.2.1

 

Troubleshooting table for alternator ............................................................................................................... 20

 

6.3

 

Engine faults ....................................................................................................................................................................... 20

 

6.3.1

 

General ............................................................................................................................................................ 20

 

6.3.2

 

Troubleshooting table for engine .................................................................................................................... 20

 

6.5

 

Warnings ............................................................................................................................................................................ 23

 

6.6

 

Service address ................................................................................................................................................................... 23

 

7

 

SPARE PARTS LIST ..................................................................................................................................................................... 24

 

 

Suppliers Declaration of Conformity/Incorporation

 

 

 

Summary of Contents for W-GV 4 Scalino

Page 1: ...UAL W GV 4 Scalino genverter OUTDOOR for mobile and land based use V1 April 2017 WHISPERPOWER BV Kelvinlaan 82 9207 JB Drachten Netherlands Tel 31 512 571550 Fax 31 512 571599 www whisperpower com Art no 40200841 ...

Page 2: ...Permanent Magnet Alternator 8 3 1 3 Engine Control Unit and DDC 8 3 1 4 Power Module Genverter 9 3 1 5 Battery charger 9 3 1 6 Load indicators 9 3 1 7 Fuel 9 3 1 8 Lubricating oil 9 3 1 9 Oil cooling heat exchanger 10 3 2 Technical data 11 3 2 1 General 11 3 2 2 Fuel specifications 13 3 2 3 Lubricating oil specifications 13 3 2 4 Electrical diagrams 13 4 OPERATION 14 4 1 General 14 4 2 Optional va...

Page 3: ...der head bolts and adjusting valve clearance 18 5 5 Putting out of service 19 6 TROUBLESHOOTING 20 6 1 General 20 6 2 Alternator electrical faults 20 6 2 1 Troubleshooting table for alternator 20 6 3 Engine faults 20 6 3 1 General 20 6 3 2 Troubleshooting table for engine 20 6 5 Warnings 23 6 6 Service address 23 7 SPARE PARTS LIST 24 Suppliers Declaration of Conformity Incorporation ...

Page 4: ...ntee period is two years limited to 1000 running hours Some aspects of our guarantee scheme are given here in more detail Guarantee does not cover failures that are caused by misuse neglect or a faulty installation WhisperPower cannot be held responsible for damage caused by the unattended running Genverter 1 4 Liability WhisperPower does not accept responsibility for damage injuries or casualties...

Page 5: ...es 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 curr...

Page 6: ...e inverter is supplying a stable 230V and 50Hz or 60Hz output while the engine is running as efficiently as possible This result in smooth running reduced vibration excellent combustion and substantial fuel savings The W GV4 can be installed with an optional variable speed control A stepper motor is installed on the speed throttle of the engine The speed is regulated by a signal from the WP PMG Wh...

Page 7: ...INFORMATION W GV4 Scalino outdoor April 2017 EN 7 2 4 Main components ...

Page 8: ...h super magnets that are used 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 includes a fan that circulates air to cool the windings Further technical data on the design of the alternator can be found in drawings and diagrams in this manual 3 1 3 Engine Contro...

Page 9: ... used with diesel fuel oil which conforms to the standards for use in modern diesel engines Fuel free from water and contaminants is of the utmost importance Detailed fuel specifications are listed in section 3 2 2 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 5B diesels is allowed as far as these B5 diesel fuels meet t...

Page 10: ...cm 2 14 psi COOLING OIL PRESSURE Minimum at idle 149 kPa 1 5 kgf cm 2 21 psi Normal at 3000 rpm 80 C 180 220 kPa 1 8 2 2 kgf cm 2 25 35 psi Maximum cooling oil pressure is protected by an overpressure switch that will trip at 550 kPa 5 5 kgf cm 2 80 psi In cold condition the pressure can be higher but the alarm will be suppressed COOLING OIL TEMPERATURE Maximum oil cooling temperature 120 C oil ou...

Page 11: ...tion degree Engine compartment IP25 Electronic compartment IP21 Max operating angle 25 in all directions Relative humidity Max 95 RH non condensing Material colour Blank brushed stainless steel engine canopy Sheet metal steel covers RAL 9010 white RAL 9020 black PMG Service interval 200h ENGINE SPECIFICATIONS Engine brand WhisperPower Engine model WP1 Intermittent power 4 8kW 6 4hp rated at 3600rp...

Page 12: ...Module Genverter 4kW frame 1 Input voltage current frequency 360 440V 11A up to 500Hz 3 wire L1 L2 L3 Output voltage current frequency 230V 16 5A 50Hz 3 wire line Neutral PE Voltage Total Harmonic Distortion nominal load 3 THD Efficiency Peak 95 average 93 Cooling Forced air cooling Generator control Local start stop local read out module Optional generator control WhisperPower DDC auto Start Stop...

Page 13: ...B252 China ISO 8217 DMX International JIS K2204 Grade No 2 Japan KSM 2610 South Korea 3 2 3 Lubricating oil specifications The engine must be run on heavy duty lubricating oil meeting the requirements of API class CH 4 CI 4 or CJ 4 It is recommended to use lubricating oil from WhisperPower or a well known brand 3 2 4 Electrical diagrams Refer to the W GV4 Scalino Installation Manual for system dra...

Page 14: ... from which the engine will be able to speed up again Example When the engine is running at no load or almost no load at 2500 rpm and a 3 kW load e g an air conditioner with an inrush current for motor starting of 4 x nominal power is switched on the engine will probably not be able to ramp up the rpm In this case the low speed setting has to be higher possibly 2800 rpm However when load steps of ...

Page 15: ...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 PMG STOP button Figure 8 and hold for 2 seconds 3 Switch to another AC power source if available 4 3 2 Extended operating instructions FIRST TIME CHECKS Check when starting the first time or after a longer period of rest 1 Check for any...

Page 16: ...mergency when there is total loss of control Act as follows 1 Prior to switching off the WP GV4 Scalino decrease the load i e turn off most electrical users and let the Scalino run at low load for approx 5 minutes to allow the engine to get properly cool the influent coolant oil must flow through the system in order to cool the engine 2 If the Genverter is operating in a hot environment and you do...

Page 17: ...ification The first time starting up or after running out of fuel it could be necessary to prime the fuel system 5 3 2 Bleeding fuel lines Ensure there is sufficient fuel The system is self bleeding The first time starting up or after running out of fuel it could be necessary to prime the fuel system Push the start button activating the electric system and activating the fuel pump When more time i...

Page 18: ... sure to retighten the cylinder head bolts before adjusting the valve clearance First remove the valve cover Loosen the bolts slightly remove the rocker assembly the rocker arms shaft and stays and then retighten the bolts to the specified torque in the numerical order illustrated Figure 9 Cylinder head bolts Tightening torques Cylinder head screws M9x1 5 47 to 51 Nm Rocker arm bracket mounting M6...

Page 19: ...ine and run the engine warm 3 Stop the engine 4 Drain the hot engine oil and refill with preservation oil 5 Open the orange oil screw plug on the cylinder cover and add 2 cc preservation oil Then rotate the engine 6 Disconnect the battery and store it in a dry place free of frost and charge it regularly 7 Close inlet and outlet openings with tape 8 Protect the Genverter against the influences of b...

Page 20: ...d adjust Alternator failure Check alternator resistance 1 4Ω Contact WhisperPower Service Genverter output voltage too low when in no load condition and RPM is above 2500 RPM Alternator failure Contact WhisperPower Service Genverter output voltage too low when under load but OK in no load condition Genverter is overloaded Switch off a load reduce number of consumers Insufficient engine RPM Increas...

Page 21: ... service department for advice Loss of compression by wear out or damage Repair by WhisperPower service 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 section 5 2 2 Choked fuel filter Check fuel filter and replace if necessary Disturbances on the electrical system user sid...

Page 22: ...m stops the engine this can be caused by oil pressure failure loose wire or faulty alarm switch Reconnect the wiring or have the system repaired by WhisperPower Faulty alarm switch sensor Replace the switch Engine stops by itself Overload or short circuit Switch off the consumers and test for short circuit If necessary contact WhisperPower service department for advice Cooling system temperature t...

Page 23: ... WhisperPower service 6 5 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 6 Service address If you cannot correct a problem with the aid of the trouble shooting tables contact your WhisperPower Service Centre or WhisperPower Netherlands for an extended service list Tel INT 31 512 571555 ...

Page 24: ...9236 Lube oil pressure switch 50209239 Cooling oil pressure switch 50209219 Temperature sensor 50212154 Fuses 3 Amps 40401060 Wiring loom 50209136 Remote control cable 10 m including connectors 40401279 Valve cover gasket 40401221 Cylinder head gasket 40401392 Cylinder head gasket kit 40401391 Sealing ring seal kit 40401020 Actuator assembly w brass spindle 40401385 Injector assembly 40401381 Fuel...

Page 25: ...spektionskategorie 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 Centre 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 ...

Page 26: ...y 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 18 4200 h 1 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 3...

Page 27: ...art 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 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 121...

Page 28: ...Kelvinlaan 82 9207 JB Drachten Netherlands Tel 31 512 571550 Fax 31 512 571599 www whisperpower com info whisperpower com ...

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