Mastervolt WHISPER 6 ULTRA User Manual
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Mastervolt WHISPER 6 ULTRA User Manual

Mastervolt WHISPER 6 ULTRA User Manual

Mobile diesel generating set 230v-50 hz
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USERS MANUAL FOR MOBILE APPLICATIONS
WHISPER 6 ULTRA
-1500 RPM-
Mobile diesel generating set 230V-50 Hz
Digital Diesel Control
MASTERVOLT
Snijdersbergweg 93
1105 AN Amsterdam
The Netherlands
Tel.: +31-20-3422100
Fax: +31-20-6971006
V1. July 2004
www.mastervolt.com

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  • Page 1 USERS MANUAL FOR MOBILE APPLICATIONS WHISPER 6 ULTRA -1500 RPM- Mobile diesel generating set 230V-50 Hz Digital Diesel Control MASTERVOLT Snijdersbergweg 93 1105 AN Amsterdam The Netherlands Tel.: +31-20-3422100 Fax: +31-20-6971006 V1. July 2004 www.mastervolt.com...

  • Page 2: Table Of Contents

    The Whisper 6 ULTRA generating set ........
  • Page 3 ..............35 EN / WHISPER 6 ULTRA Mobile / July 2004...

  • Page 4: Introduction

    INTRODUCTION 1 INTRODUCTION GENERAL GUARANTEE The Whisper 6 ULTRA Mobile Diesel Generating set is Mastervolt guarantees that this generating set has been manufactured and marketed by Mastervolt. built according to good workmanship, according to the It is important to read this manual before installing and specifications in this manual and according to European operating the generating set.

  • Page 5: Liability

    225 kg by additional measures. Mastervolt does not accept liabi- lity for damage due to use of the generator, possible errors Fig. 1: Nameplate. in the manuals and the results thereof. EN / WHISPER 6 ULTRA Mobile / July 2004...

  • Page 6: Information

    230V available on a vehicle. Put warning signs on wall sockets and on 2.1.3 Earth insulation failures junction boxes. Instruct non-regular users According to local regulations and depending on the ap- July 2004 / WHISPER 6 ULTRA Mobile / EN...

  • Page 7: Installation

    Do not smoke or allow sparks, flames, or other External moving parts like fans and V-belts are covered sources of ignition around batteries. by the canopy and therefore the Whisper 6 ULTRA is very safe, when the canopy is closed •...

  • Page 8: Transport Lifting And Storage

    After 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 weeks. July 2004 / WHISPER 6 ULTRA Mobile / EN...

  • Page 9: Components

    35 RPM adjustment screw; 36 Thermostat housing; 37 Alternator; 38 Filling cap coolant; 40 Drain plug coolant; 41 Stop lever; 42 Oil filter. 43 Digital Diesel Control Unit Fig. 2: Overview Whisper 6 ULTRA. EN / WHISPER 6 ULTRA Mobile / July 2004...

  • Page 10: Generator Control Panel

    The 5 Failure lamp; voltage is regulated at 14.2V. 6 Generator load indicator. 7 Display 2.5.5 Alarms and shut down In the event of malfunctioning this will be indicated by the July 2004 / WHISPER 6 ULTRA Mobile / EN...

  • Page 11: Alarms And Shut Down

    The Mitsubishi engine valves leaving the connection to the expansion tank must be run on heavy duty lubricating oil meeting the open. requirements of API class CC or CD. EN / WHISPER 6 ULTRA Mobile / July 2004...

  • Page 12: Technical Data

    225 kg including canopy Max. installation angle 25 degrees Standard supplies remote panel (+15 m cable), fuel filter, fuel lift pump, user and installation manuals Optional installation kits, non earth return, spare part kits July 2004 / WHISPER 6 ULTRA Mobile / EN...

  • Page 13: Wiring Codes And Colours

    1,5 mm2 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 6 ULTRA Mobile / July 2004...

  • Page 14: Lay Out Control Wiring 12V

    RED 1,5 (14) BLACK 4 (2)J17 WHITE 1,5 (18) RED 2,5 (1) RED 25 RED 2,5 (13) RED 6 (21) MASTERVOLT TAILOR MADE ENERGY YELLOW 2,5 (4) Fig. 7: Lay out control PCB. July 2004 / WHISPER 6 ULTRA Mobile / EN...
  • Page 15 GREY 1,5 (5) GREY 1,5 (5) RED 1,5 (14) BLACK 4 (2)J17 WHITE 1,5 (18) RED 2,5 (1) RED 25 RED 2,5 (13) RED 6 (21) MASTERVOLT TAILOR MADE ENERGY YELLOW 2,5 (4) EN / WHISPER 6 ULTRA Mobile / July 2004...
  • Page 16 GREY 1,5 (5) GREY 1,5 (5) RED 1,5 (14) BLACK 4 (2)J17 WHITE 1,5 (18) RED 2,5 (1) RED 25 RED 2,5 (13) RED 6 (21) MASTERVOLT TAILOR MADE ENERGY YELLOW 2,5 (4) July 2004 / WHISPER 6 ULTRA Mobile / EN...

  • Page 17: Electrical Diagram 230V 50Hz

    (11) 230V 50Hz DCC/ct-1 MAIN WINDING ROTOR BROWN YELLOW/GREEN BLUE MAIN WINDING DCC/AC-1 YELLOW/GREEN EARTH AND NEUTRAL CONNECTED CURRENT TRANSFORMER BLACK (11) (11) 230V 50Hz DCC/ct-1 BROWN YELLOW/GREEN BLUE DCC/AC-1 YELLOW/GREEN EN / WHISPER 6 ULTRA Mobile / July 2004...

  • Page 18: Diagram Fan Control

    6,3A 6,3A 12VDC 230VAC CU1,5 CU0,75 CU1,5 CU0,75 CU0,75 CU1.5 CU1.5 DIMENTION BOX: 270x270x180 MM 45-35?C 80-70?C 230VAC 230VAC POWER SUPPLY 230 VAC MAIN CIRCUIT BREAKER GENERATOR CIRCUIT BREAKER AIRFAN AIRFAN July 2004 / WHISPER 6 ULTRA Mobile / EN...
  • Page 19 FUSE 20/40A 80-70∞C 45-35∞C THERMOSTAT COOLER RADIATOR COOLER ENGINE ALTERNATOR ENGINE ALTERNATOR TERMINAL BLOCK JUCTION BOX AIR FANS CU0,75 CU2,5 CU0,75 CU0,75 CU2.5 FUSE 20/40A 80-70∞C 45-35∞C DIMENIONS BOX: 160x160x90 MM EN / WHISPER 6 ULTRA Mobile / July 2004...

  • Page 20: Operation

    In operation checks: Source Selector switch to "OFF" or switch off all de- 1 Check for abnormal noise or vibration vices. 2 Check the voltage 5 Switch on the battery switch. July 2004 / WHISPER 6 ULTRA Mobile / EN...
  • Page 21 Please note this when switching on your electrical devices! Nevertheless, the Whisper is designed so as not to overheat, even under extreme conditions. EN / WHISPER 6 ULTRA Mobile / July 2004...

  • Page 22: Maintenance And Care

    Push the glow button activating the electric system and activating the fuelpump. Retighten the bleed screw when no further air bubbles are expelled. Fig. 12. July 2004 / WHISPER 6 ULTRA Mobile / EN...

  • Page 23: Readjusting V-Belt

    Install the new impeller and add some grease. Turn the 2 Min. oil level. blades in the direction of rotation of the pump i.e. anti Fig. 15. clockwise looking at the impeller. EN / WHISPER 6 ULTRA Mobile / July 2004...

  • Page 24: Maintenance Schedule

    Clean radiator with compressed air 1000 hours Retighten cylinder head bolts, adjust valve clearance 1000 hours Replace the V-belt 1000 hours Check injector and injection pressure 2000 hours Check inlet air filter 2000 hours July 2004 / WHISPER 6 ULTRA Mobile / EN...

  • Page 25: Trouble Shooting

    • Disturbances on the electrical system/ Check if electrical load is fluctuating. user side. • Engine runs irregular. When engine runs irregular refer to section: "Engine runs irregular" in engine faults. EN / WHISPER 6 ULTRA Mobile / July 2004...

  • Page 26: Engine Malfunctions

    Check fuel filter and fuel lift pump: clean or • Fuel filter is blocked. replace if necessary. • Air in fuel lines. Bleed air from fuel system (refer to maintenance section). July 2004 / WHISPER 6 ULTRA Mobile / EN...
  • Page 27 Bypassing the failure, lack of coolingwater switches can help to identify the failure. (exhaust temperature alarm) Loose wire or faulty alarm switch. Digital Diesel Control will identify failure EN / WHISPER 6 ULTRA Mobile / July 2004...
  • Page 28 Check and refer to installation manual. • Hot air circulation in radiator • Broken or slipping V-belt. Replace and adjust the V-belt tension. • Faulty thermostat. Check the thermostat or replace. July 2004 / WHISPER 6 ULTRA Mobile / EN...

  • Page 29: Warnings

    5.4.1 Setting the RPM When the diode is faulty, the alternator will not generate RPM is set by the manufacturer and should not need any voltage. readjustment! However a very slight offset after running EN / WHISPER 6 ULTRA Mobile / July 2004...

  • Page 30: Valve Clearance / Retightening Cylinder Head Bolts

    5 nuts are well accesible. The sixth nut has to be removed by taking out the bold from the bottom of the canopy. Fig. 19. July 2004 / WHISPER 6 ULTRA Mobile / EN...
  • Page 31 5 The rotor can be taken off by removing the bolt which check very carefully for leakages before putting it goes through the shaft (normal clockwise threaded). back in its enclosure. EN / WHISPER 6 ULTRA Mobile / July 2004...

  • Page 32: Spare Parts List

    Nozzle injector, 3pcs (**) 50204160 Fuel pump (high pressure) complete 50203045 Thermostat (**) 50203038 Gasket thermostat (**) 50204037 Gasket rocker cover (**) More extensive partslist on the internet: mastervolt.com (fast moving parts) July 2004 / WHISPER 6 ULTRA Mobile / EN...
  • Page 33 50209015 O-ring, 1x 50209017 Bearing, 2x 50209014 Clip, 2x 50209019 Clip, 1x 50209016 Shaft type M 1x 50201811 O-ring, 1x 50201814 Clamp, 4x 50201815 Impeller kit: impeller + gasket + screw EN / WHISPER 6 ULTRA Mobile / July 2004...

  • Page 34: Maintenance Log

    INFORMATION LOG first service after 50 hours: hour counter: remarks: next service (every 150 hours) hour counter: remarks: July 2004 / WHISPER 6 ULTRA Mobile / EN...

  • Page 35: Notes

    NOTES EN / WHISPER 6 ULTRA Mobile / July 2004...
  • Page 36 MASTERVOLT Snijdersbergweg 93, 1105 AN Amsterdam, The Netherlands Tel.: +31-20-3422100 / Fax: +31-20-6971006 www.mastervolt.com / info@mastervolt.com July 2004 / WHISPER 6 ULTRA Mobile / EN...

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