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Mastervolt WHISPER 3,5

Mastervolt WHISPER 3,5
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MASTERVOLT
Snijdersbergweg 93
1105 AN Amsterdam
The Netherlands
Tel.: +31-20-3422100
Fax: +31-20-6971006
www.mastervolt.com
USERS MANUAL U.S.A. EDITION
V1.April 2004
WHISPER 3,5
-3600 RPM-
Marine diesel generating set 120V / 60 Hz
Digital Diesel Control
Art.no. 50200307

Table of Contents

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Mastervolt WHISPER 3,5 Specifications

General IconGeneral
BrandMastervolt
ModelWHISPER 3, 5
CategoryInverter
LanguageEnglish

Summary

OPERATION

General Operation

General overview of the generating set's operational readiness.

Operating Instructions

Detailed steps for operating the generating set.

MAINTENANCE AND CARE

Engine Maintenance

Maintenance and servicing for the diesel engine.

INTRODUCTION

General Introduction

General information about the Whisper 3,5 generating set.

Service and Maintenance

Guidelines for regular service and maintenance procedures.

Guarantee

Details about the product warranty and its conditions.

IDENTIFICATION AND LIABILITY

Nameplate Details

Details found on the generator's nameplate for identification.

Liability and Warnings

Mastervolt's disclaimer of responsibility and safety warnings.

INFORMATION AND SAFETY

General Safety Guidelines

General safety guidelines and warnings for operation.

Electrical Safety Precautions

Specific safety measures related to electrical hazards.

OPERATIONAL SAFETY

Fire and Explosion Prevention

Safety measures to prevent fire and explosion risks.

Chemical Handling Safety

Safety measures for handling chemicals and fluids.

TRANSPORT, LIFTING AND STORAGE

Safe Lifting Procedures

Safe procedures for lifting and handling the generating set.

Long-Term Storage Guidelines

Guidelines for storing the generator for extended periods.

WHISPER 3,5 FEATURES

Key Technical Features

Key features and design aspects of the Whisper 3,5.

COMPONENTS AND TECHNICAL INFO

Main Components Identification

Identification and description of the main components of the generator.

Generator Control Panel

Overview of the generator's control panel.

TECHNICAL INFORMATION

AC Alternator Specifications

Technical details of the single-phase synchronous alternator.

Engine Specifications

Details of the Kubota OC60 diesel engine used.

Digital Diesel Control System

Overview of the microprocessor-based control system.

TECHNICAL INFORMATION (Continued)

Battery Charger Functionality

Information on the integrated battery charging system.

Alarms and Shut Down System

Functions and indicators for alarms and automatic shutdown.

Fuel and Oil Specifications

Requirements for fuel and lubricating oil.

TECHNICAL DATA SUMMARY

General and Electrical Specs

General technical specifications and electrical parameters.

Mechanical Specifications

Mechanical details, dimensions, and included parts.

WIRING CODES AND COLOURS

AWG Wire Gauge Information

Explanation of wire codes, colours, and AWG sizes.

LAY OUT CONTROL PCB

Control PCB Diagram

Diagram showing the layout of the control printed circuit board.

ELECTRICAL DIAGRAM 120 V AC 60 HZ

AC 60 Hz Electrical Schematic

Schematic diagram for the 120V AC 60Hz electrical system.

OPERATION INSTRUCTIONS

Summarised Daily Instructions

Concise daily operating procedures for quick reference.

Extended Operating Guidance

In-depth guidance for initial or long-term use.

OPERATION CHECKS AND LOAD MANAGEMENT

Checks During Operation

Checks to perform while the generator is running.

Engine Load Management

Guidelines for managing engine load during operation.

STOPPING THE GENERATING SET

Proper Shutdown Procedure

Recommended steps for safely stopping the generating set.

MAINTENANCE PROCEDURES

Engine Maintenance Details

Detailed maintenance procedures for the diesel engine.

Valve Clearance Adjustment

How to check and adjust engine valve clearances.

REGULAR MAINTENANCE SCHEDULE

Daily Checks

Routine checks to be performed daily.

100 Hour Service

Maintenance tasks required every 100 operating hours.

300 Hour Service

Maintenance tasks required every 300 operating hours.

PERIODIC MAINTENANCE SCHEDULE

1000 & 2000 Hour Service

Maintenance tasks required every 1000 and 2000 operating hours.

Putting Out of Service

Procedures for storing the generator for extended periods.

TROUBLE SHOOTING: ALTERNATOR FAULTS

AlternatorElectrical Troubleshooting

Troubleshooting guide for alternator and AC electrical issues.

Troubleshooting Table

A table listing problems, causes, and solutions.

TROUBLE SHOOTING: ENGINE FAULTS

Engine Faults Checklist

A checklist for diagnosing engine faults.

Failure Codes Explained

Explanation of error codes displayed by the control system.

TROUBLESHOOTING ENGINE STARTING & RUNNING

Engine Fails to Start

Common causes and solutions when the engine does not start.

Engine Runs Irregularly

Troubleshooting steps for irregular engine operation.

Engine Speed Drops

Diagnosing and resolving issues with engine speed reduction.

TROUBLESHOOTING POWER & EXHAUST ISSUES

Engine Stop Issues

Troubleshooting when the engine fails to stop correctly.

Sooty Black Exhaust

Identifying and resolving issues causing black exhaust smoke.

Loss of Power Diagnosis

Diagnosing and fixing causes of power loss.

SPECIAL PROCEDURES: ALTERNATOR

Residual Voltage Check

Procedure for checking and restoring residual voltage.

Testing Rotary Diodes

Steps for testing rotary rectifier diodes.

SPECIAL PROCEDURES: ENGINE

Setting Engine RPM

How to adjust the engine's RPM setting.

Measuring Exhaust Backpressure

Method for measuring exhaust system backpressure.

DISASSEMBLING INSTRUCTIONS

Removing the Generating Set

Step-by-step guide for safely removing the set from its enclosure.

SPARE PARTS LIST

Recommended Spare Parts

List of recommended spare parts for maintenance.

Part Numbers and Descriptions

Detailed list of parts with article numbers and descriptions.

SPARE PARTS: WATER PUMP TYPE K

Water Pump Components

List of spare parts for the water pump type K.

MAINTENANCE LOG

Service Schedule Recording

Log for recording service intervals and remarks.

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