Measuring Exhaust By Backpressure; Disassembly Instructions - Mastervolt WHISPER 9,5 ULTRA User Manual

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 stroke.
After adjusting the valves of cylinder 1 adjust the valve
clearance of the remaining cylinders in firing order 1 - 3 -
2. Turn the crankshaft 240º clockwise from the T.D.C of
cylinder 1 to the T.D.C of cylinder 3. Adjusts the valves
of cylinder 3 and turn the crankshaft further clockwise to
the T.D.C of cylinder 2.
5.4.3 measuring exhaust backpressure
The exhaust system must be of adequate size -
2"/ 51 mm - and maximal length (refer to installation
manual). When any doubt; backpressure has to be
measured. An easy way to measure for back-pressure is
to use a water column.
Fig. 21: Measuring exhaust backpressure
A water column can be made visible in a plastic tube
along a yardstick and fitting the end to a hose connection
to fit in the adaptor on the injection bent after removing
the exhaust temperature switch.
The bent A hanging down should not be to short helping
to damp the pulsating effect of the gas discharge. The
water column should be no more than 27 inches (69 cm.)
of water (1 PSI - 0,07 bar)
5.4.4. Disassembling instructions
It could be necessary for repair or checks to disassemble
the generating set.
USA / WHISPER 15 ULTRA / May 2004
Following instructions will help:
1 The design of the Whisper 15 makes it possible to do
most repairs on the spot. The heatexchanger is
accessible and can be removed. The connections of
the alternator are very accessible as well. The same
is true for the diode of the rotor.
2 To take the generating set out of the canopy all hose
and cable connections has to be taken off. The set is
fixed to its base by four rubber mountings and can be
taken loos by removing the four nuts from the bolts of
this mountings. Moreover the generating set is fixed
by 2 fail safes that prevents the generating set of
getting loose when the rubber mountings would 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.
3 The easiest way to get the generator out of its cap-
sule is by lifting the set with aid of the lifting eyes and
take away the capsule downwards.
4 The cooler elements are welded to the alternator hou-
69
27
sing with silver and cannot be disassembled. How-
ever one can take off the complete alternator hou-
sing.
5 Before the alternator can be taken off one has to take
out the fitting to the heatexchanger to be able to take
off the metal cover. All cables and wiring has to be
taken loose first.
6 The rotor can be taken off by removing the bold which
goes through the shaft (normal clockwise threaded).
The end of the shaft is specially threaded to push off
the rotor from the conic stub shaft, which is on the
flywheel, using a 0,39 inch (10 mm) rod of 6,9 inch
(175 mm) length and a M24x2 bolt.
7 Reassembling the generating set one should take
care for alignment cleaning the surfaces between en-
gine and alternator and tighten the bolds crosswise
and gradually.
8 Use Loctite 577 to seal the fittings, which should first
be cleaned and made free of oil and grease.
9 Test the generating set first outside its capsule and
check very carefully for leakages before putting it
back in its enclosure.
TROUBLE SHOOTING
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