Table of Contents
Troubleshooting
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Summary of Contents for Mastervolt WISPER 8ULTRA 1500 RPM
- Page 1 USERS MANUAL WHISPER 8 / 10 ULTRA - 1500 RPM - Marine diesel generating set 230V / 50Hz Digital Diesel Control MASTERVOLT Snijdersbergweg 93, 1105 AN Amsterdam The Netherlands Tel.: +31-20-3422100 Fax.: +31-20-6971006 V3 December 2009 www.mastervolt.com...
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Page 2: Table Of Contents
Oil information ..........................13 2.5.12 Cooling liquid........................... 13 2.5.13 Technical data ..........................14 2.5.14 Wiring codes and colours ........................ 15 2.5.15 Lay out control wiring........................16 December 2009 / WHISPER 8 & 10 ULTRA / EN / Copyright © 2009 Mastervolt... - 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 ..............................36 MAINTENANCE LOG ................................38 EN / WHISPER 8 & 10 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 December 2009 / WHISPER 8 & 10 ULTRA / EN / Copyright © 2009 Mastervolt... -
Page 5: Liability
The cost for returning faulty goods is not covered under guarantee. Additional agreements could be part of the contract of delivery. EN / WHISPER 8 & 10 ULTRA / December 2009 / Copyright © 2009 Mastervolt... -
Page 6: Identification
Check the settings (voltage, frequency, rpm) Example: when there is any doubt. SERIAL NO: : WO22A001 version “A” December 2009 / WHISPER 8 & 10 ULTRA / EN / Copyright © 2009 Mastervolt... -
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 8 & 10 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 December 2009 / WHISPER 8 & 10 ULTRA / EN / 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 EN / WHISPER 8 & 10 ULTRA / December 2009 / Copyright © 2009 Mastervolt... -
Page 10: Components
(Whisper 10 Ultra) Fuel filter Engine oil filter Fuel lift pump Oil sump hand pump Fig. 4: Rear view main components Whisper 8Ultra and 10Ultra. December 2009 / WHISPER 8 & 10 ULTRA / EN / Copyright © 2009 Mastervolt... - Page 11 Filler cap engine coolant Rocker cover Filler cap engine oil Temperature switch Thermostat housing Failsafe Rubber engine mounting Fig. 6: Top View main components Whisper 8Ultra and 10Ultra EN / WHISPER 8 & 10 ULTRA / December 2009 / Copyright © 2009 Mastervolt...
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Page 12: Generator Control Panel
Display On the engine is an alternator generating 50 Amp 12V. This current is rectified to charge the battery. The voltage is regulated at ±14.4V. December 2009 / WHISPER 8 & 10 ULTRA / EN / Copyright © 2009 Mastervolt... -
Page 13: Alarms And Shut Down
Fill up till the level is just below the filling cap. When the engine is on temperature the liquid will expand and the EN / WHISPER 8 & 10 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 December 2009 / WHISPER 8 & 10 ULTRA / EN / Copyright © 2009 Mastervolt... -
Page 15: Wiring Codes And Colours
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 8 & 10 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 8 and 10 Ultra December 2009 / WHISPER 8 & 10 ULTRA / EN / Copyright © 2009 Mastervolt... -
Page 17: Electrical Diagram 230 V Ac / 50 Hz
INFORMATION 2.5.16 Electrical diagram 230 V AC / 50 Hz Figure 7: Electrical diagram 230 V AC / 50 Hz EN / WHISPER 8 & 10 ULTRA / December 2009 / Copyright © 2009 Mastervolt... -
Page 18: Diagram Electronic Governor Whisper 10 Ultra
The electronic governor system contains two parts: The actuator controls the engine speed. This actuator replaces the standard hold solenoid that is on all other Figure 8: Diagram electronic governor December 2009 / WHISPER 8 & 10 ULTRA / EN / Copyright © 2009 Mastervolt... -
Page 19: Operation
Therefore we recommend daily oil-checks. Check oil level prior to starting the engine or at least 5 minutes after the engine has stopped. EN / WHISPER 8 & 10 ULTRA / December 2009 / Copyright © 2009 Mastervolt... - Page 20 December 2009 / WHISPER 8 & 10 ULTRA / EN / Copyright © 2009 Mastervolt...
- Page 21 Press the STOP button. Close the inlet sea water cock. Switch to an other 230V power source, if available. If a Masterswitch is installed, this is done automatically. EN / WHISPER 8 & 10 ULTRA / December 2009 / Copyright © 2009 Mastervolt...
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Page 22: Maintenance
(so not on the remote Fig. 17 panel) Hold as long as necessary to bleed the system. Retighten the bleed screw when no further air bubbles are expelled. December 2009 / WHISPER 8 & 10 ULTRA / EN / Copyright © 2009 Mastervolt... -
Page 23: Readjustment V-Beltplacing Oil Filter
Turn the blades in the the mark direction of rotation of the pump i.e. anti clockwise looking at the impeller. Minimum oil level Maximum oil level Fig. 20: EN / WHISPER 8 & 10 ULTRA / December 2009 / Copyright © 2009 Mastervolt... -
Page 24: Maintenance Schedule
When the generator set runs less than 100 hours a year the oil should be changed yearly December 2009 / WHISPER 8 & 10 ULTRA / EN / Copyright © 2009 Mastervolt... -
Page 25: Putting Out Of Service
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. EN / WHISPER 8 & 10 ULTRA / December 2009 / Copyright © 2009 Mastervolt... -
Page 26: Trouble Shooting
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 December 2009 / WHISPER 8 & 10 ULTRA / EN / Copyright © 2009 Mastervolt... -
Page 27: Trouble Shooting Table
"soft-start". Inquire at your nearest Mastervolt dealer or directly at the manufacturer, Mastervolt in the Netherlands. EN / WHISPER 8 & 10 ULTRA / December 2009 / Copyright © 2009 Mastervolt... -
Page 28: 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 December 2009 / WHISPER 8 & 10 ULTRA / EN / Copyright © 2009 Mastervolt... -
Page 29: Trouble Shooting Table
• Choked exhaust system, exhaust Check the exhaust hose blocked, rubber exhaust hose kinked. • Air in the fuel pipes Bleed air from fuel system (refer to maintenance section). EN / WHISPER 8 & 10 ULTRA / December 2009 / Copyright © 2009 Mastervolt... - Page 30 • Air or water in the fuel. • Blocked air or fuel filter. • Loss of compression by wear out or Repair by Mastervolt service. damage. December 2009 / WHISPER 8 & 10 ULTRA / EN / Copyright © 2009 Mastervolt...
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Page 31: Warnings
● Motor RPM suddenly rises or drops. ● Unusual noise comes from generating set. ● Exhaust gases suddenly colour dark. ● Engine failure warning light is on EN / WHISPER 8 & 10 ULTRA / December 2009 / Copyright © 2009 Mastervolt... -
Page 32: Special Procedures Alternator
When readings are infinity but a fault is suspected one can do a high voltage resistance test (MEGGERING) This procedure should be carried out by an expert December 2009 / WHISPER 8 & 10 ULTRA / EN / Copyright © 2009 Mastervolt... -
Page 33: Special Procedures Engine
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. EN / WHISPER 8 & 10 ULTRA / December 2009 / Copyright © 2009 Mastervolt... -
Page 34: Measuring Exhaust Backpressure
The water column should be no more than 27 inches (69 cm.) of water (1 PSI - 0,07 bar) December 2009 / WHISPER 8 & 10 ULTRA / EN / Copyright © 2009 Mastervolt... - Page 35 SPARE PARTS LIST Figure 27: exploded view sound shield Whisper 8 and 10 Ultra EN / WHISPER 8 & 10 ULTRA / December 2009 / Copyright © 2009 Mastervolt...
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Page 36: Spare Parts List
Fuel pump (high pressure) complete (***) 50205045 Thermostat (**) 50205038 Gasket thermostat (**) 50207037 Gasket rocker cover (**) More extensive parts list on the internet: MASTERVOLT.COM (fast moving parts) December 2009 / WHISPER 8 & 10 ULTRA / EN / Copyright © 2009 Mastervolt... - Page 37 SPARE PARTS LIST Figure 28: Raw water pump complete Mastervolt type M12 EN / WHISPER 8 & 10 ULTRA / December 2009 / Copyright © 2009 Mastervolt...
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Page 38: Maintenance Log
MAINTENANCE LOG MAINTENANCE LOG first service after 50 hours: hour counter: remarks next service (every 150 hours) hour counter: remarks December 2009 / WHISPER 8 & 10 ULTRA / EN / Copyright © 2009 Mastervolt... - Page 39 NOTES NOTES EN / WHISPER 8 & 10 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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