Mastervolt WHISPER 16 ULTRA User Manual
Marine diesel generating set 230-50 hz digital diesel control
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- User manual (44 pages) ,
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- Installation manual (40 pages)
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Summary of Contents for Mastervolt WHISPER 16 ULTRA
- Page 1 USERS MANUAL WHISPER 16 ULTRA - 1500 RPM - Marine diesel generating set 230-50 Hz Digital Diesel Control MASTERVOLT Snijdersbergweg 93, 1105 AN Amsterdam The Netherlands Tel.: +31-20-3422100 Fax.: +31-20-6971006 V5. December 2009 www.mastervolt.com...
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Page 2: Table Of Contents
Load indicator ..........................13 2.5.10 Fuel specification..........................13 2.5.11 Oil information ..........................13 2.5.12 Cooling liquid........................... 13 2.5.13 Technical data ..........................14 2.5.14 Wiring codes and colours ........................ 15 Copyright © 2009 Mastervolt / December 2009 / WHISPER 16 ULTRA / EN... - Page 3 Adjusting valve clearance and retightening the cylinder head bolts..........32 5.4.3 Measuring exhaust backpressure....................33 5.4.4 Disassembling instructions ......................33 SPARE PARTS LIST ..............................35 MAINTENANCE LOG ................................37 EN / WHISPER 16 ULTRA / December 2009 / Copyright © 2009 Mastervolt...
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Page 4: Introduction
Sometimes the seal of the raw water pump starts leaking. life. Mostly this begins with a little drip and slowly gets worse. Regular visual inspection of the generator is necessary to Copyright © 2009 Mastervolt / December 2009 / WHISPER 16 ULTRA / EN... -
Page 5: Liability
In all these cases the guarantee may become invalid. Use original spareparts only! EN / WHISPER 16 ULTRA / December 2009 / Copyright © 2009 Mastervolt... -
Page 6: Identification
SERIAL NO: : W822B001 settings. Check the settings (voltage, frequency, rpm) when there is any doubt. version “B” Copyright © 2009 Mastervolt / December 2009 / WHISPER 16 ULTRA / EN... -
Page 7: Information
Warning signs indicate parts which could be battery, proper fitting of the cooling system and fuel pipes live. etc. Refer to the installation manual. EN / WHISPER 16 ULTRA / December 2009 / Copyright © 2009 Mastervolt... -
Page 8: Operation
When exposed to abnormal high temperatures in • Keep a fire extinguisher on hand. excess of 400°C an extremely corrosive acid is produced which cannot be removed from the Copyright © 2009 Mastervolt / December 2009 / WHISPER 16 ULTRA / EN... -
Page 9: Transport, Lifting And Storage
2.3.4 Accessories included in the standard delivery • Expansion tank, hose and fittings • Special hose connector for measuring exhaust back pressure (refer to paragraph 5.4.3) EN / WHISPER 16 ULTRA / December 2009 / Copyright © 2009 Mastervolt... -
Page 10: Components
Filler cap engine oil Rocker cover Filler cap engine coolant Temperature switch coolant Engine oil pressure switch Engine serial number Fig. 4: Rear view main components Whisper 16Ultra. Copyright © 2009 Mastervolt / December 2009 / WHISPER 16 ULTRA / EN... - Page 11 Engine Oil Dipstick Fuel bleeding screw Starter motor solenoid Starter motor Fuel lift pump for manual priming Fuel injection pump Fig. 6: Front view main components Whisper 16Ultra EN / WHISPER 16 ULTRA / December 2009 / Copyright © 2009 Mastervolt...
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Page 12: Generator Control Panel
Fig. 11: Digital Diesel remote control panel engine will be shut down. There are three functions Copyright © 2009 Mastervolt / December 2009 / WHISPER 16 ULTRA / EN... -
Page 13: Control
When the cooling is based on keel cooling or radiator cooling the EN / WHISPER 16 ULTRA / December 2009 / Copyright © 2009 Mastervolt... -
Page 14: Technical Data
Digital remote panel (+15 m cable), fuel filter, fuel lift pump, user and installation manuals Optional: Installation kits, mobile (vehicle) version, non earth return (ungrounded), spare part kits, PTO to drive a hydraulic pump Copyright © 2009 Mastervolt / December 2009 / WHISPER 16 ULTRA / EN... -
Page 15: Wiring Codes And Colours
DDC > LCP red/green 1,5 mm2 DDC > generator AC output brown 1 mm2 DDC > generator AC output blue 1 mm2 DDC=Digital Diesel Control Unit LCP=Local Control Panel EN / WHISPER 16 ULTRA / December 2009 / Copyright © 2009 Mastervolt... -
Page 16: Lay Out Control Wiring
INFORMATION 2.5.15 Lay out control wiring Fig 12: Electrical Diagram control wiring Whisper 16Ultra Copyright © 2009 Mastervolt / December 2009 / WHISPER 16 ULTRA / EN... -
Page 17: Electrical Diagram 230 V Ac / 50 Hz
INFORMATION 2.5.16 Electrical diagram 230 V AC / 50 Hz Figure 13: Electrical diagram 230 V AC / 50 Hz EN / WHISPER 16 ULTRA / December 2009 / Copyright © 2009 Mastervolt... -
Page 18: Diagram Electronic Governor (Optional)
50 Hz of the AC more stable frequency and voltage and more power. output voltage as a reference. Fig 14: Diagram electronic governor Copyright © 2009 Mastervolt / December 2009 / WHISPER 16 ULTRA / EN... -
Page 19: Operation
Switch on battery switch (when installed). Fuel valve: open. Starting: Push the start button to initiate the full automatic starting procedure. You can monitor the procedure on the display. EN / WHISPER 16 ULTRA / December 2009 / Copyright © 2009 Mastervolt... - Page 20 For instance; a bent piston rod or a cracked cylinder head. In fact water in the cylinder is the main cause for engine damage in pleasure craft. Copyright © 2009 Mastervolt / December 2009 / WHISPER 16 ULTRA / EN...
- Page 21 Only disconnect the battery with the engine stopped and all switches in "OFF" position EN / WHISPER 16 ULTRA / December 2009 / Copyright © 2009 Mastervolt...
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Page 22: Maintenance
When the engine is in cold condition both valves (inlet and outlet) should have a clearance between 0.25 mm. The adjustment has to be done at TDC (refer to § 5.4.2). Copyright © 2009 Mastervolt / December 2009 / WHISPER 16 ULTRA / EN... -
Page 23: Replacing Fuel Filter
A smeer of oil has to be put on the seal of the filter before fitting the filter. The filter should be fastened manually: when the rubber touches the metal turn 3/4 further. Fig. 18 EN / WHISPER 16 ULTRA / December 2009 / Copyright © 2009 Mastervolt... -
Page 24: Regular Maintenance
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 Copyright © 2009 Mastervolt / December 2009 / WHISPER 16 ULTRA / EN... -
Page 25: Maintenance Schedule
Replace the V-belt 1000 hours Check lubricating oil pressure 2000 hours Check injector and injection pressure 2000 hours Check inlet air filter 2000 hours Check cooling system 2000 hours EN / WHISPER 16 ULTRA / December 2009 / Copyright © 2009 Mastervolt... -
Page 26: Trouble Shooting
• Engine is not reaching the rated RPM. Refer to engine RPM problems In no load condition it is ok • Defective capacitor Check capacitor and replace if necessary (refer to special procedures). Copyright © 2009 Mastervolt / December 2009 / WHISPER 16 ULTRA / EN... -
Page 27: Engine Faults
Generator AC output voltage is either too high or too low AC VOLTAGE Generator is in overload HIGH CURRENT Output frequency of the generator is too low FREQUENCY EN / WHISPER 16 ULTRA / December 2009 / Copyright © 2009 Mastervolt... -
Page 28: Trouble Shooting Table
• Air in the fuel pipes Bleed air from fuel system (refer to maintenance section). • Blocked injector. Have the injector tested and cleaned if necessary. Copyright © 2009 Mastervolt / December 2009 / WHISPER 16 ULTRA / EN... - Page 29 Check thermostat and replace • Generator is being overloaded. Digital Sooty, black exhaust. Check electrical load and switch off some consumers Diesel Control will indicate “ HIGH ”. CURRENT EN / WHISPER 16 ULTRA / December 2009 / Copyright © 2009 Mastervolt...
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Page 30: Warnings
● Motor RPM suddenly rises or drops. ● Unusual noise comes from generating set. ● Exhaust gases suddenly colour dark. ● Engine failure warning light is on Copyright © 2009 Mastervolt / December 2009 / WHISPER 16 ULTRA / EN... -
Page 31: Special Procedures Alternator
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. Fig. 22 EN / WHISPER 16 ULTRA / December 2009 / Copyright © 2009 Mastervolt... -
Page 32: Special Procedures Engine
It is very important to identify the correct setting assembly (refer to fig. 23). The screw is to be locked in position with the lock-nut. Fig. 25 Finding TDC Copyright © 2009 Mastervolt / December 2009 / WHISPER 16 ULTRA / EN... -
Page 33: Measuring Exhaust Backpressure
The water column should be no more than 27 inches (69 cm.) of water (1 PSI - 0,07 bar) EN / WHISPER 16 ULTRA / December 2009 / Copyright © 2009 Mastervolt... - Page 34 SPARE PARTS LIST Figure 27: exploded view sound shield Whisper 16Ultra Copyright © 2009 Mastervolt / December 2009 / WHISPER 16 ULTRA / EN...
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Page 35: Spare Parts List
Nozzle injector, 4pcs (**) 50206045 Thermostat (**) 50206038 Gasket thermostat (**) 50206034 Gasket rocker cover (**) More extensive parts list on the internet: MASTERVOLT.COM (fast moving parts) EN / WHISPER 16 ULTRA / December 2009 / Copyright © 2009 Mastervolt... - Page 36 SPARE PARTS LIST Figure 28: Raw water pump complete Mastervolt type M16 Copyright © 2009 Mastervolt / December 2009 / WHISPER 16 ULTRA / EN...
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Page 37: Maintenance Log
MAINTENANCE LOG MAINTENANCE LOG first service after 50 hours: hour counter: remarks next service (every 150 hours) hour counter: EN / WHISPER 16 ULTRA / December 2009 / Copyright © 2009 Mastervolt... - Page 38 NOTES NOTES Copyright © 2009 Mastervolt / December 2009 / WHISPER 16 ULTRA / EN...
- Page 39 NOTES NOTES EN / WHISPER 16 ULTRA / December 2009 / Copyright © 2009 Mastervolt...
- Page 40 Snijdersbergweg 93, 1105 AN Amsterdam, The Netherlands Tel : + 31-20-3422100 Fax : + 31-20-6971006 Email : info@mastervolt.com...
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