Mastervolt WHISPER 6 User Manual

Marine diesel generating set 120/240v / 60hz

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Page 1 USERS MANUAL U.S.A EDITION WHISPER 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 V8. July 2009 www.mastervolt.com...
Page 2: Table Of Contents
CONTENTS This manual applies to the Mastervolt Whisper 6, 8 and 11, 3600rpm marine generating set controlled by Digital Diesel Control. First launched in April 2004. For earlier models refer to other manuals available on our website: www.mastervolt.com Copyright © 2009 Mastervolt. All rights reserved.
Page 3 Adjusting valve clearance and retightening the cylinder head bolts..........33 5.4.3 Measuring exhaust backpressure....................34 5.4.4 Disassembling instructions ......................34 SPARE PARTS LIST ..............................35 MAINTENANCE LOG ................................37 US / WHISPER 6/8/11 / July 2009 / Copyright © 2009 Mastervolt...
Page 4: Introduction
USA. 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. July 2009 / WHISPER 6/8/11 / US / Copyright © 2009 Mastervolt...
Page 5: Liability
If after the faulty goods are returned, it is indicated that the failure was not covered by guarantee a credit will not be issued. For example if a US / WHISPER 6/8/11 / July 2009 / Copyright © 2009 Mastervolt...
Page 6: Identification
When this number is available the manufacturer can settings. Check the settings (voltage, frequency, rpm) trace the specifications of the generating set. On the when there is any doubt. July 2009 / WHISPER 6/8/11 / US / Copyright © 2009 Mastervolt...
Page 7: Information
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. US / WHISPER 6/8/11 / July 2009 / Copyright © 2009 Mastervolt...
Page 8: Operation
750°F (400°C) an extremely corrosive acid is produced which cannot be removed from the skin. If signs of decomposition are evident, or if in doubt, always wear disposable heavy duty gloves. July 2009 / WHISPER 6/8/11 / US / Copyright © 2009 Mastervolt...
Page 9: Transport, Lifting And Storage
2.3.4 Accessories included in the standard delivery • Special hose connector for measuring exhaust backpressure • Expansion tank, hose and fittings US / WHISPER 6/8/11 / July 2009 / Copyright © 2009 Mastervolt...
Page 10: Components
37 Alternator; 38 Filling cap coolant; 39 Heat exchanger; 40 Drain plug coolant; 41 Stop lever; 42 Oil filter; 43 Digital Diesel Control unit. Fig. 2: Overview Whisper 6/8/11 July 2009 / WHISPER 6/8/11 / US / Copyright © 2009 Mastervolt...
Page 11: Generator Control Panel
Refer to the separate Select button; Digital Diesel Control users manual. Set button; Failure lamp; The microprocessor unit is located on top of the alternator. Generator load indicator. Display US / WHISPER 6/8/11 / July 2009 / Copyright © 2009 Mastervolt...
Page 12: Battery Charger
The remote control offers several timer functions that help The engine is cooled by cooling liquid. The capacity of this to schedule maintenance. system of the Whisper 6-8 is 2.1 U.S.qts (2 litres) and of the Whisper 11 3.7 U.S.qts (3.5 litres).. 2.5.9...
Page 13: Technical Data
Standard supplies remote panel (+15 m cable), fuel lift pump, expansion tank Optional mobile Installation kits, mobile (vehicle) version, non earth return, spare part kits * Electronic governor US / WHISPER 6/8/11 / July 2009 / Copyright © 2009 Mastervolt...
Page 14: Wiring Codes And Colours
DDC > generator AC output blue 1 mm2 DDC > generator AC output brown 1 mm2 DDC > generator AC output blue 1 mm2 DDC=Digital Diesel Control Unit LCP=Local Control Panel July 2009 / WHISPER 6/8/11 / US / Copyright © 2009 Mastervolt...
Page 16: Electrical Diagram 120-240 V Ac / 60 Hz
INFORMATION 2.5.16 Electrical diagram 120-240 V AC / 60 Hz Fig. 11: Electrical diagram 120 - 240V July 2009 / WHISPER 6/8/11 / US / Copyright © 2009 Mastervolt...
Page 17: Diagram Electronic Governor
60 Hz of the AC So the electronic governor offers three advantages: a output voltage as a reference. more stable frequency and voltage and more power. Fig 8: Diagram electronic governor US / WHISPER 6/8/11 / July 2009 / Copyright © 2009 Mastervolt...
Page 18: 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. July 2009 / WHISPER 6/8/11 / US / Copyright © 2009 Mastervolt...
Page 19: Extended Operating Instructions
Running for long periods at no load or light chapter). load in the first 50 hours can cause cylinder glazing and high oil consumption. US / WHISPER 6/8/11 / July 2009 / Copyright © 2009 Mastervolt...
Page 21: Maintenance
Start / Stop button on the Local control panel pushed. Hold as long as necessary to bleed the system. Retighten the bleed screw when no further air Figure 11 bubbles are expelled. US / WHISPER 6/8/11 / July 2009 / Copyright © 2009 Mastervolt...
Page 22: Readjustment Of The V-Belt
Check and readjust V-belt • Check impeller raw water pump (durability depends on the purity of the sea water. In sandy water and warm water wear will increase). July 2009 / WHISPER 6/8/11 / US / Copyright © 2009 Mastervolt...
Page 23: Maintenance Schedule
When overhauling the engine one could clean the parts thoroughly or replace. When the generator set runs less than 100 hours a year the oil should be changed yearly US / WHISPER 6/8/11 / July 2009 / Copyright © 2009 Mastervolt...
Page 24: Putting Out Of Service
Drain the water from the water lock. Repeat steps 2, 3, and 4, every 6 months. Change oil Crank the engine having the raw water inlet sucking before using the engine again. July 2009 / WHISPER 6/8/11 / US / Copyright © 2009 Mastervolt...
Page 25: Trouble Shooting
• Engine is not reaching the rated RPM. Refer to special procedures to readjust RPM. than 105V / 210V). • Defective capacitor. Check capacitor and replace if necessary (refer to special procedures). US / WHISPER 6/8/11 / July 2009 / Copyright © 2009 Mastervolt...
Page 27: Engine Faults
If the voltage does not drop during starting, the electrical connection is faulty. If the battery voltage drops lower than 11V, then the battery has been discharged too deep. US / WHISPER 6/8/11 / July 2009 / Copyright © 2009 Mastervolt...
Page 28 • Defective generator (windings, Generator must be sent to manufacturer for repair of damaged bearing or winding. bearings or other) • Damaged engine Repair by Mastervolt service July 2009 / WHISPER 6/8/11 / US / Copyright © 2009 Mastervolt...
Page 29 When any doubt, measure the power directly with an appropriate instrument. • Overfull oil sump. Bring the oil to the correct level • Choked fuel filter. Replace the fuel filter. US / WHISPER 6/8/11 / July 2009 / Copyright © 2009 Mastervolt...
Page 30: Warnings
+31-20-3422100. ● Motor RPM suddenly rises or drops. ● Unusual noise comes from generating set. ● Exhaust gases suddenly colour dark. ● Engine failure warning light is on July 2009 / WHISPER 6/8/11 / US / Copyright © 2009 Mastervolt...
Page 31: Special Procedures Alternator
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. US / WHISPER 6/8/11 / July 2009 / Copyright © 2009 Mastervolt...
Page 32: Winding Resistant Values
2= adjustment screw RPM 3= manual stop It is very important to identify the correct setting assembly (refer to fig. 17).The screw is to be locked in position with the lock-nut. July 2009 / WHISPER 6/8/11 / US / Copyright © 2009 Mastervolt...
Page 33: Adjusting Valve Clearance And Retightening The Cylinder Head Bolts
T.D.C. mark (notch) on the crankshaft pulley with the mark on the gear case (ref. to fig. 20). Fig. 19a: Fig. 19b: 2 cylinder engine 3 cylinder engine US / WHISPER 6/8/11 / July 2009 / Copyright © 2009 Mastervolt...
Page 34: Measuring Exhaust Backpressure
Test the generating set first outside its capsule and check very carefully for leakages before putting it back in its enclosure. July 2009 / WHISPER 6/8/11 / US / Copyright © 2009 Mastervolt...
Page 35: Spare Parts List
SPARE PARTS LIST 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.
Page 37: Maintenance Log
MAINTENANCE LOG MAINTENANCE LOG first service after 50 hours: hour counter: remarks next service (every 150 hours) hour counter: US / WHISPER 6/8/11 / July 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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Whisper 8 Whisper 11

Mastervolt WHISPER 6 User Manual

1 Introduction

2 Information

3 Operation

4 Maintenance

5 Trouble Shooting

6 Spare Parts List

Maintenance Log

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Troubleshooting

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