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SPARE PARTS LIST

US / WHISPER 6/8/11 / July 2009 / Copyright © 2009 Mastervolt

35

6 SPARE PARTS LIST

A parts manual in English is available as an option number: number: 50200381 (***)(Whisper 6 and 8); 50200382(***)
(Whisper 11). A work shop manual in English is available as an option number: 50200171.
We recommend the following spares for service and maintenance.
• Kit A: parts for regular maintenance parts (Whisper 6, 8 and 11) marked

(*)

article no. 50201860

• Kit B: parts for maint spare parts:(Whisper 6 and 8) all parts market

(*)+(**)

article no. 50201861

• Kit C: parts for "world travellers" all parts market (Whisper 6 and 8)

(*)+(**)+(***)

article no. 50201862

• Kit B: parts for maint spare parts: all parts market (Whisper 11)

(*)+(**)

article no. 50201761

• Kit C: parts for "world travellers" all parts market (Whisper 11)

(*)+(**)+(***)

article no. 50201762

ARTICLE NO

DESCRIPTION

50209030

Fuel filter (*)

50201031

Fuel lift pump (***)

50203120

V-belt (*)

50203121

Oil filter (*)

50201850

Raw water pump complete Mastervolt type M (***) (refer to fig. 21)

50209011

Im gasket (*) (4,3,5)

50201812

Cover type M (**) (2)

50209018

Bolts cover (**) (1) (6 pcs.)

50201851

Pump repair kit A consisting of: Shaft (50201811), Bearings (2 pcs) (50209014), O-ring (50209017),
Seals (2 pcs.) (50209015), Clips (1 set) (50209019), O-ring (50201814)

50209010

Pump repair kit B (**)(same as repair kit A excluding the shaft(50201811) and O-ring (50201814))

50201820

Heat exchanger complete with appendages (Whisper 6 and 8)(***)

50201822

Water hoses with clamps (Whisper 6 and 8) (**)

50201720

Heat exchanger complete with appendages (Whisper 11)(***)

50201722

Water hoses with clamps (Whisper 11) (**)

50201060

Capacitor xx micro-farad, 2 pcs (**) (xx = give value when ordering)

50209132

Measuring coil (***)

50201890

Rotary diode (**)

50201887

Alternator bearing including O-ring (**)

50209140

Voltage regulator (Whisper 8 and 11)(optional)

50209104

Local control panel (***)

50209100

Digital Diesel Control Unit (***)

50212170

Fuses 10 Amps(*)

50212154

Fuses 3 Amps (*)

50201886

Wiring loom complete (***)

50209102

Digital Diesel Remote control panel (***)

130010915

Cable remote control 15 mtr, including connectors

50203033

Overhaul gasket kit / Sealkit (Whisper 6 and 8) (***)

50203030

Cylinder head gasket kit (Whisper 6 and 8)

50204033

Overhaul gasket kit / Sealkit (Whisper 11) (***)

50204030

Cylinder head gasket kit (Whisper 11)

50203040

Glow plug, 2 pcs (Whisper 6 and 8) (**); 3pcs (Whisper 11) (**)

50203050

Nozzle injector, 2 pcs (Whisper 6 and 8) (**); 3pcs (Whisper 11) (**)

50203160

Fuel pump (high pressure) complete (Whisper 6 and 8) (***)

50204160

Fuel pump (high pressure) complete (Whisper 11) (***)

50203045

Thermostat (**)

50203038

Gasket thermostat (**)

50203037

Gasket rockercover (Whisper 6 and 8) (**)

50204037

Gasket rockercover (Whisper 11) (**)

50209051

Silicone O-ring soundshield cover (**)

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

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Содержание WHISPER 11

Страница 1: ...PER 6 8 11 3600 RPM Marine diesel generating set 120 240V 60Hz Digital Diesel Control MASTERVOLT Snijdersbergweg 93 1105 AN Amsterdam The Netherlands Tel 31 20 3422100 Fax 31 20 6971006 www mastervolt com V8 July 2009 Art nr 50200354 ...

Страница 2: ...5 2 Identification plate 6 2 INFORMATION 7 2 1 Safety 7 2 1 1 General 7 2 1 2 Electrical safety 7 2 1 3 Earth insulation failures 7 2 1 4 Installation 7 2 1 5 Operation 8 2 1 6 Fire and explosion 8 2 1 7 Chemicals 8 2 2 Transport lifting and storage 9 2 3 The Whisper 6 8 11 9 2 3 1 Features 9 2 3 2 Remote control 9 2 3 3 Documentation 9 2 3 4 Accessories included in the standard delivery 9 2 4 Com...

Страница 3: ... Readjustment of the V belt 22 4 3 Regular maintenance 22 4 3 1 Maintenance schedule 23 4 3 2 Putting out of service 24 5 TROUBLE SHOOTING 25 5 1 Alternator electrical faults 25 5 1 1 General 25 5 1 2 Trouble shooting table 25 5 2 Engine faults 27 5 2 1 General 27 5 2 2 Trouble shooting table 27 5 2 3 Warnings 30 5 2 4 Service address 30 5 3 Special procedures alternator 31 5 3 1 Residual voltage ...

Страница 4: ...er distributor or dealer in any circumstances shall be held liable for any inaccuracy or the consequences thereof WARNING A warning symbol draws attention to special warnings instructions or procedures which if not strictly observed may result in damage or destruction of equipment severe personal injury or loss of life DANGER This danger symbol refers to electric danger and draws attention to spec...

Страница 5: ... labour needed to get access to the generator for example to remove equipment or bulkheads etc For details refer to Mastervolt U S A Goods to be delivered under guarantee will be invoiced Only after the faulty goods are returned will the invoice be credited Payment in advance may be required or guaranteed by credit card If after the faulty goods are returned it is indicated that the failure was no...

Страница 6: ...C For higher temperatures the generating set has to be derated 3 VOLTAGE shows the nominal voltage This voltage should be within the specified tolerance at the nominal frequency 4 FREQUENCY is shown in Hz and is determined by the speed of the engine RPM 50 Hz correlates with 3000 rpm 60 Hz correlates with 3600 rpm 5 CURRENT shows the maximum current that is acceptable at the specified frequency vo...

Страница 7: ...king on the electrical system the 3 Amp fuse must be removed from the control panel and the battery plus cable must be removed from the battery Warning signs indicate parts which could be live 2 1 3 Earth insulation failures According to local regulations and depending on the application it could be necessary to take measures for protection against earth insulation failures With the USA versions n...

Страница 8: ...k of fire and explosion Avoid refilling the fuel tank while the engine is running When oil or fuel is leaking do not use the generating set Do not run the engine close to explosives or gasses Hydrogen gas generated by charging batteries is explosive Ensure for proper ventilation Do not smoke or allow sparks flames or other sources of ignition around batteries Keep a fire extinguisher on hand Poor ...

Страница 9: ...base frame and mounted securely on anti vibration mounting pads to the capsule base All cables and hoses are guided through the capsule s left side The set is not self contained and is only operable after proper installation using additional accessories and installation materials Installation accessories are listed in the installation manual and are available through the supplier of the genera tin...

Страница 10: ... Electric fuel lift pump 21 Raw water pump 22 Cooling liquid temperature switch 23 Fuel pressure pump 24 Oil pressure switch 25 Oil sump pump 26 Exhaust connection 27 Fuel vent screw 28 Oil level indicator 29 Control panel 30 Capacitors optional voltage regulator for Whisper 8 11 31 Fuse 1 32 Fuse 2 33 Remote control cable 34 Cooling water injection 35 RPM adjustment screw 36 Thermostat housing 37...

Страница 11: ... of load switching to relieve the burden on the engine The Whisper 8 and 11 can be equipped with an optional voltage regulator to keep the voltage tolerance within 2 Further technical data on the design of the alternator can be found in drawings and diagrams in this manual 2 5 2 Engine The Whisper 6 and 8 generating set is based on the Mitsubishi L2E 2 cylinder diesel engine The Whisper 11 on the ...

Страница 12: ... Fuel specification The engine must only be used with diesel fuel oil which conforms to the standards for use in modern diesel engines Fuel free from water and contaminants is of the utmost importance 2 5 11 Oil information 1 Specification The oil must be suitable for oil changes as specified in the maintenance chapter The engine must be run on heavy duty lubricating oil meeting the requirements o...

Страница 13: ...75 cu inch 635 cm3 58 09 cu inch 952 cm3 Bore X stroke 2 99 x 2 76 inch 76x70 mm 2 99 x 2 76 inch 76x70 mm 2 99 x 2 76 inch 76x70 mm Combustion air consumption 40cf m 1 1 m3 min 40cf m 1 1 m3 min 60cf m 1 7 m3 min Continuous power engine 6 kW 7 4 kW 11 kW Cooling system indirect cooling by raw water 2 6 3 5US qpm 10 14 l min Cooling water pump PTO driven Mastervolt self priming impeller pump type ...

Страница 14: ...e black 17 1 mm2 DDC exhaust temperature switch 8 blue green 17 1 mm2 DDC fuel solenoid hold 9 green 16 1 5 mm2 DDC fuel solenoid pull 20 pink 16 1 5 mm2 DDC fuel solenoid com 17 black 16 1 5 mm2 B terminal alternator starter motor 21 red 10 6 mm2 DDC R terminal alternator 18 white 16 1 5 mm2 DDC L terminal alternator 19 orange 16 1 5 mm2 DDC current measuring transformer 11 black 17 1 mm2 DDC cur...

Страница 15: ...INFORMATION US WHISPER 6 8 11 July 2009 Copyright 2009 Mastervolt 15 2 5 15 Lay out control wiring Fig 6 Lay out control wiring ...

Страница 16: ...INFORMATION 16 July 2009 WHISPER 6 8 11 US Copyright 2009 Mastervolt 2 5 16 Electrical diagram 120 240 V AC 60 Hz Fig 11 Electrical diagram 120 240V ...

Страница 17: ...will bring more power So the electronic governor offers three advantages a more stable frequency and voltage and more power The electronic governor system contains two parts 1 The actuator controls the engine speed This actuator replaces the standard hold solenoid that is on all other mechanical controlled Whisper engines The actuator controls the RPM directly on the fuel rack inside the fuel pump...

Страница 18: ... the start button to initiate the full automatic starting procedure You can monitor the procedure on the display In operation checks 1 Check for abnormal noise or vibration 2 Check the voltage 3 Check sea water flow at exhaust outlet 4 Power source selector switch off shore power generator power Switch to power source generator If a Mass Systemswitch is installed this operates automatically 5 Befo...

Страница 19: ...me the fuel system Refer to bleeding fuel system instructions in the maintenance chapter A restart protection prevents starting the engine when it is already running which could cause damage In the event of starting problems numerous attempts are made close the sea water inlet cock while cranking to prevent the outlet system and engine to fill up with water During the starting process the cooling ...

Страница 20: ...ing at too low load will cause the exhaust to be choked by carbon Never remove the battery while the engine is running or any electrical cable while the battery is connected in the circuit Only disconnect the battery with the engine stopped and all switches in OFF position Stopping the generating set 1 Avoid stopping of the generator abruptly after a long period of operation at high load Doing so ...

Страница 21: ...linder glazing and high oil consumption For the same reason it is of the greatest importance to use the right oil specification The first time starting up or after running out of fuel it could be necessary to prime the fuel system 4 2 2 Bleeding fuel lines Ensure there is sufficient fuel The system is self bleeding The first time starting up or after running out of fuel it could be necessary to pr...

Страница 22: ... fill up with fresh oil Start the engine again and have it run for 5 minutes Stop the engine again and pause for a few minutes to let the oil gather in the crankcase Check the level again and add oil when necessary Check and tighten nuts bolts and unions paying particular attention to the fuel system Observe the exhaust at the normal full load The exhaust must be free from soot Do not allow the en...

Страница 23: ... replaced Check the cooling system The engine cooling liquid is indirectly cooled by raw water via a heat exchanger The alternator is cooled by seawater which is pumped by the PTO driven impeller pump through the cooler elements in the generator housing All parts of the cooling system are of corrosion free and seawater resistant materials such as brass and gunmetal In case of gathering of dirt in ...

Страница 24: ...n oil 4 Stop the engine and take loose the inlet of the raw water pump Drain the water from the water lock Crank the engine having the raw water inlet sucking anti freeze from a can until the pump heat exchanger and manifold are filled 5 The coolant can stay in the engine 6 Disconnect the battery and store it in a place free of frost and dry and charge it regularly 7 Close inlet and outlet opening...

Страница 25: ...ptable Therefore a no load setting should be at 3636 RPM 60 6 Hz Under no circumstances should the RPM under full load be below 3560 RPM 59 4 Hz When the problem is in the RPM refer to the engine fault finding paragraph Digital Diesel Control system will help to indicate failures and display causes Failure code Problem COMMUNICATION Communication error between the panel end the generator LOW START...

Страница 26: ...y Presence of a strong capacitive load leading power factor Compensate for this capacity and seek for experts advice MASTERVOLT customers service Generator voltage too high more than 130V 250V Defective voltage regulator Optional for Whisper 8 and Whisper 11 Replace voltage regulator Disturbances on the electrical system user side Check if electrical load is fluctuating Generator voltage fluctuate...

Страница 27: ...temperature is too high OIL PRESSURE Oil pressure failure AC VOLTAGE Generator AC output voltage is either too high or too low HIGH CURRENT Generator is in overload FREQUENCY Output frequency of the generator is too low 5 2 2 Trouble shooting table Problem Possible cause What to do Almost certainly this is an electrical problem Display will indicate LOW START BAT One other possibility is that the ...

Страница 28: ...nsuitable contaminated fuel Lack of fuel Fill up with fuel or replace by better quality Choked fuel filter Check fuel filter and fuel lift pump clean or replace if necessary Faulty fuel lift pump Check and repair Choked air filter Lack of air Check the air intake Choked exhaust system exhaust blocked rubber exhaust hose kinked Check the exhaust hose Air in the fuel pipes Bleed air from fuel system...

Страница 29: ...ure switch tripped Check oil level Check engine s oil pressure and have it repaired by Mastervolt Excessive heat in cooling system thermo switch tripped Lack of cooling water exhaust switch tripped Impeller broken Cooling water blocked Water strainer blocked Air or water in the fuel Blocked air or fuel filter Check cooling water system flow water pump inlet water filter coolant flow Loss of compre...

Страница 30: ...lease air bubbles Check if there are air blocks in the system refer to the installation manual Water inlet system blocked Broken impeller Water strainer choked Heat exchanger choked Check the cooling system thoroughly Broken or slipping V belt Replace and adjust the V belt tension Over temperature Faulty thermostat Check the thermostat or replace 5 2 3 Warnings Generator must be shut off immediate...

Страница 31: ...re and injuries When flashing does not bring back voltage the capacitor s should be renewed When this does not help the rotating rectifier diodes should be tested and a winding resistant test should be executed 5 3 2 Testing rotary rectifier diodes The diodes in the rotor can be checked with a multimeter When the diode is faulty the alternator will not generate any voltage The flexible lead connec...

Страница 32: ...finity but a fault is suspected one can do a high voltage resistance test MEGGERING This procedure should be carried out by an expert 5 4 SPECIAL PROCEDURES ENGINE 5 4 1 Setting the RPM RPM is set by the manufacturer and should not need readjustment However a very slight offset after running in could occur RPM can be measured by a frequency meter Whisper 8 and 11 When adjustments are necessary thi...

Страница 33: ...irst align the T D C mark for the No 1 cylinder Confirm that the valves do not move up or down when the crankshaft is turned about 20 degrees in normal and reverse direction of rotation If the rocker arms move piston no 1 is on the T D C of the intake or exhaust stroke In such case turn the crankshaft 360 in the direction of engine rotation again No 1 piston is now at T D C of the compression stro...

Страница 34: ...ntings should break down The nuts of the fail safes are diagonal to each other When the 6 nuts in total are removed the generating set can be lifted out the canopy 5 nuts are well accessible The sixth nut has to be removed by taking out the bold from the bottom of the canopy 2 The easiest way to get the generator out of its capsule is by lifting the set using the lifting eye and removing the capsu...

Страница 35: ... as repair kit A excluding the shaft 50201811 and O ring 50201814 50201820 Heat exchanger complete with appendages Whisper 6 and 8 50201822 Water hoses with clamps Whisper 6 and 8 50201720 Heat exchanger complete with appendages Whisper 11 50201722 Water hoses with clamps Whisper 11 50201060 Capacitor xx micro farad 2 pcs xx give value when ordering 50209132 Measuring coil 50201890 Rotary diode 50...

Страница 36: ...SPARE PARTS LIST 36 July 2009 WHISPER 6 8 11 US Copyright 2009 Mastervolt ...

Страница 37: ...MAINTENANCE LOG US WHISPER 6 8 11 July 2009 Copyright 2009 Mastervolt 37 MAINTENANCE LOG first service after 50 hours hour counter remarks next service every 150 hours hour counter ...

Страница 38: ...NOTES 38 July 2009 WHISPER 6 8 11 US Copyright 2009 Mastervolt NOTES ...

Страница 39: ...NOTES US WHISPER 6 8 11 July 2009 Copyright 2009 Mastervolt 39 NOTES ...

Страница 40: ...Snijdersbergweg 93 1105 AN Amsterdam The Netherlands Tel 31 20 3422100 Fax 31 20 6971006 Email info mastervolt com ...

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