Mastervolt WHISPER 6 ULTRA User manual

MASTERVOLT
Snijdersbergweg 93
1105 AN Amsterdam
The Netherlands
Tel.: [phone]
Fax: [phone]
www.mastervolt.com
USERS MANUAL FOR MOBILE APPLICATIONS
V1. July 2004
WHISPER 6 ULTRA
-1500 RPM-
Mobile diesel generating set 230V-50 Hz
Digital Diesel Control
Art.nr. 50200329

2July 2004 / WHISPER 6 ULTRA Mobile / EN
CONTENTS
This manual applies to the Mastervolt Whisper 6 ULTRA mobile
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
CONTENTS
1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.2 Service and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.3 Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.4 Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.5 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.5.2 Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2 INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2.1.2 Electrical safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2.1.3 Earth insulation failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2.1.4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.1.5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.1.6 Fire and explosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.1.7 Chemicals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.2 Transport lifting and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
2.3 The Whisper 6 ULTRA generating set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
2.3.1 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
2.3.2 Remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
2.3.3 Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
2.4 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
2.4.1 Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
2.4.2 Generator control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
2.4.3 Remote control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
2.5 Technical information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
2.5.1 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
2.5.2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
2.5.3 DC electrical control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
2.5.4 Battery charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
2.5.5 Alarms and shut down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
2.5.6 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
2.5.7 Remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
2.5.8 Hour counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
2.5.9 Load indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
2.5.10 Fuel specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
2.5.11 Oil specification, oil viscosity, oil capacity,, oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
2.5.12 Cooling liquid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
2.5.13 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

EN / WHISPER 6 ULTRA Mobile / July 2004 3
CONTENTS
2.5.14 Wiring, codes and colours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
2.5.15 Lay out control Wiring 12V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
2.5.16 Electrical diagram 230V 50Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
2.5.17 Diagram fan control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
3.2 Operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
3.2.1 Summarised operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
3.2.2 Extended operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
4 MAINTENANCE AND CARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
4.1 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
4.2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
4.2.1 General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
4.2.2 Bleeding fuel lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
4.2.3 Valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
4.2.4 Replacing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
4.2.5 Replacing the oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
4.2.6 Readjusting V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
4.3 Regular maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
4.3.1 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
4.3.2 Putting out of service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
5 TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
5.1 Alternator malfucntions / AC trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
5.1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
5.1.2 Trouble shooting check list alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
5.2 Engine malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
5.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
5.2.2 Trouble shooting check list engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
5.2.3 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
5.2.4 Service address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
5.3 Special procedures alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
5.3.1 Residual voltage check / excitation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
5.3.2 Testing rotary diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
5.3.3 Windings resistance values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
5.3.4 Meggering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
5.4 Special procedures engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
5.4.1 Readjusting RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
5.4.2 Valve clearance / retightening cylinder head bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
5.4.3 Measuring exhaust by backpressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
5.4.4 Disassembly instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
6 SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Maintenance log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

4July 2004 / WHISPER 6 ULTRA Mobile / EN
INTRODUCTION
1 INTRODUCTION
1.1 GENERAL
The Whisper 6 ULTRA Mobile Diesel Generating set is
manufactured and marketed by Mastervolt.
It is important to read this manual before installing and
operating the generating set. Both safety and durability
rely very much on the correct identification, installation
and a good understanding of ratings, features, design,
maintenance and operation procedures.
The information, specifications, illustrations and state-
ments contained within this publication are given with our
best intentions and are believed to be correct at the time
of going to press.
Our policy is one of continued development and we re-
serve the right to amend any technical information with-
out prior notice.
Whilst every effort is made to ensure the accuracy of the
particulars contained within this publication neither the
manufacturer, distributor, or dealer in any circumstances
shall be held liable for any inaccuracy or the consequen-
ces thereof.
WARNING:
A warning symbol draws attention to spe-
cial warnings, instructions or procedures
which, if not strictly observed, may result in
damage or destruction of equipment, seve-
re personal injury or loss of life.
DANGER:
This danger symbol refers to electric dan-
ger and draws attention to special war-
nings, instructions or procedures which, if
not strictly observed, may result in electri-
cal shock which will result in severe per-
sonal injury or loss of life.
Realise that people are not used to have
230V available on a vehicle. Put warning
signs on wall sockets and on junction
boxes. Instruct non-regular users of the
vehicle. Warn maintenance personal of
garages that do service on the vehicle.
1.2 SERVICE AND MAINTENANCE
Regular service and maintenance should be executed
according to the directions in this manual. For service
and maintenance one can appeal to the manufacturer or
the dealers.
1.3 GUARANTEE
Mastervolt guarantees that this generating set has been
built according to good workmanship, according to the
specifications in this manual and according to European
Community safety regulations.
During production and prior to delivery, all of our genera-
ting sets are tested and inspected.
The well functioning of this generating set is subject to
guarantee. The period and conditions of this guarantee
are laid down in the general conditions of delivery as
registered with the Chamber of Commerce and Industries
in Amsterdam number 33279951 and are available on
request. The guarantee period is two years, limited to
1000 running hours. Some aspects of the warranty
scheme are given here in more detail:
Guarantee period 1000 running hours or 24 months
whichever occurs first. Warrantee does not cover failures
that are caused by misuse or a faulty installation.
Example 1. Faulty installation:
Overheating of the engine is the most common cause of
problems with mobile generating sets. These problems are
caused by poor circulation of the cooling liquid due to
incorrectrouting of the pipes to the radiators: bends will
capture air bubbles causing “air-locks” blocking the
circulation of the liquid. Other examples of installation
problems are hot air circulation into the radiators and the
radiator fans sucking exhaust gases into the radiators.
The generator and other parts should be protected against
the influences of the weather and splashing water (with dirt
and salt) below the vehicle. Refer to the installation manual.
Example 2: Misuse:
Long term running with no load or too little load can
cause the exhaust to get choked with soot or carbon.
Cleaning the exhaust is not covered by warrantee.
Example 3: Neglect
Whisper generators have an option for an auto start/stop
mode or interval mode.
Mastervolt cannot be held responsible for damage
caused by the unattended running generator.
Warranty means that faulty parts are repaired or replaced
free of charge. If necessary the whole generator unit will
be exchanged. Labour necessary to complete repairs on

EN / WHISPER 6 ULTRA Mobile / July 2004 5
INTRODUCTION
board a vehicle executed by an authorised service
engineer is covered, but is limited to a reasonable
number of hours and reasonable rates in relation to the
actual repair work that has to be done.
Travel expenses and travel hours are not covered. Also
not covered is the labour required to take a generator out
of a vehicle or for reinstallation. There is no cover for
labour needed to get access to the generator, for
example to remove equipment or parts of the carroserie
etc.
Goods to be delivered under warrantee will be invoiced.
Only after the faulty goods are returned will the invoice
be credited. Payment in advance may be required or
guaranteed by credit card. If after the faulty goods are
returned, it is indicated that the failure was not covered
by warranty a credit will not be issued. For example if a
Printed Circuit Board is returned with clear damage
caused by water, warranty will be refused.
Freight costs to deliver spares by normal mail or carriers
is covered under warranty. Special services like express
mail, overnight delivery etc. are not covered. Taxes and
duties are not covered. For shipments to remote off
shore areas any additional costs incurred over normal
carriage will be invoiced to the customer.
The cost for returning faulty goods is not covered under
warranty.
If any problem arise which could be subject of guarantee,
procedures should be followed as described in the gua-
rantee certificate, unauthorised repairs could lead to furt-
her damage and violate the guarantee conditions and are
not refunded.
Should work take place, which is not in ac-
cordance with the guidelines, instructions
and specifications contained in this user’s
manual and the supplementary installation
manual, then damage may occur and the
generating set may not fulfil its specifica-
tions. In all these cases the guarantee may
become invalid. Use original parts only.
1.4 LIABILITY
Mastervolt does not accept responsibility for damage,
injuries or casualties which are the result of operation of
the generating set in specific conditions which brings
dangers which could not be foreseen, or could be avoided
by additional measures. Mastervolt does not accept liabi-
lity for damage due to use of the generator, possible errors
in the manuals and the results thereof.
Automatic start/stop
Mastervolt cannot be held responsible for damage
caused by the unattended running generator using
the auto-start/stop mode or interval mode.
1.5 IDENTIFICATION
1.5.1 general
Before using this generating set it is very important to
identify the set correctly. To communicate for service or
ordering parts it is also essential to correctly identify the
generating set. Also for the daily operation of the genera-
ting set it is necessary that the operator knows the cor-
rect specifications.
1.5.2 Nameplate
All required identification data are on the nameplate.
1 The identity of the generating set is given by the SE-
RIAL NUMBER.
When this number is available the manufacturer can
trace the specifications of the generating set. On the
nameplate are also some basic features of the set:
2 POWER
The nameplate gives the nominal maximum load in
kVA = kW calculated with the indicated power factor
one. When calculating a load one should always take
into account the power factor or Cos phi of this load.
810x525x615 mm
25 A
5,7 kW at cos phi = 1
50905020
Whisper 6 ULTRA
225 kg
230 V
50 Hz
SINGLE PHASE
PHASE
DIMENSIONS
WxDxH
WEIGHT
ARTICLE NO
MODEL
SERIAL NUMBER
MAX. POWER
VOLTAGE
FREQUENCY
CURRENT
Fig. 1: Nameplate.

6July 2004 / WHISPER 6 ULTRA Mobile / EN
2 INFORMATION
2.1 SAFETY
2.1.1 General
When correctly installed and used in normal circumstan-
ces this generating set fulfils EC safety regulations. This
generating set could be part of an installation or could be
used in a way that additional regulations of the EC or
other authorities have to be taken into account.
Circumstances could make it also neces-
sary to take additional measures. Be awa-
re of wet conditions and hazardous envi-
ronment caused by explosive gases etc.
2.1.2 Electrical safety
The voltage of 230 Volt generated by this
generating set is dangerous and if instruc-
tions and procedures are not strictly obser-
ved may result in electrical shock which
will result in severe personal injury or loss
of life.
Remember that people are not used to
have 230V available on a vehicle. Put
warning signs on wall sockets and on
junction boxes. Instruct non-regular users
of the vehicle. Warn maintenance personal
of garages that do service on the vehicle.
• Check all wiring at least once a year. Defects,
such as loose connections, burned cables etc.
must be repaired immediately.
• Do not work on the electrical system if it is still
connected to a current source. Only allow chan-
ges in your electrical system to be carried out by
qualified electricians.
•Using the auto-start/stop (interval) mode the
generator can start unexpectedly. When
working on the electrical system, the 3 Amp
fuse must be removed from the control panel
and the battery plus cable must be removed
from the battery.
• Connection and protection must be done in accor-
dance with local standards.
Warning signs indicate parts which could
be live.
2.1.3 Earth insulation failures
According to local regulations and depending on the ap-
INFORMATION
The power should never exceed the nominal Power
in kW as shown on the nameplate. Power is rated at
an ambient temperature of 40°C and a seawater tem-
perature of 25ºC. For higher temperatures the gene-
rating set has to be derated.
3 VOLTAGE shows the nominal voltage.
This voltage should be within the specified tolerance
at the nominal frequency.
4 FREQUENCY is shown in Hz and is determined by
the speed of the engine (RPM). 50 Hz correlates with
1500 rpm.
5 CURRENT shows the maximum current that is ac-
ceptable at the specified frequency, voltage and po-
wer factor.
6 WEIGHT shows the net dry weight (approximately) in
kg. This is without fuel, oil, cooling liquid, packing and
external installation equipment.
7 The CE symbol shows that the generating set is build
according to European Community safety regulations.
This includes the regulations regarding the safety of
pleasure craft, machinery, regarding electric safety
and electric magnetic compatibility (EMC).
Safety also relies on the installation, application and cir-
cumstances. See also the remarks in this manual under
SAFETY
Before changing a factory setting you are advised to con-
sult the manufacturer. When the generating set you have
to identify is not new you have to take into account the
possibility that former users may have changed the
settings. Check the settings (voltage, frequency, rpm)
when any doubt.

EN / WHISPER 6 ULTRA Mobile / July 2004 7
INFORMATION
plication it could be necessary to take measures for
protection against earth insulation failures.
In the standard delivery “neutral” and “ground” are not
connected. To make a connection between “neutral” and
“ground” could be necessary as part of a specific
insulation failure protection system.
In all situations the transfer switches
between shore, inverter and generator
should switch both neutral and L1. Of
course this is the case when using a
Mastervolt Masterswitch.
2.1.4 Installation
Whisper generating sets are not self contained and have
to be properly installed in enclosed areas. Installation
includes measures to be taken to outlet exhaust fumes
which contains carbon monoxide and are extremely
dangerous. Carbon monoxide (CO) is an invisible
odourless gas. Inhalation produces headache, nausea or
death. Installation includes measures for proper
ventilation, safe electric connections, safe installation of
the starting battery, proper fitting of the cooling system
and fuel pipes etc. Refer to the installation manual.
Do not use the generator set when the
vehicle is inside a building or in other
enclosed area’s.
Be aware when using the generator in still
conditions, as the exhaust fumes could
accumulate under, around or even in the
vehicle.
2.1.5 Operation
External moving parts like fans and V-belts are covered
by the canopy and therefore the Whisper 6 ULTRA is
very safe, when the canopy is closed
Nevertheless take note of the signs on the
generating set which shows symbols in a
triangle indicating danger.
• When service has to be executed while the
engine is running, be aware of moving parts like
V-belts.
• The generating set should be operated by authori-
sed personnel only.
• Be aware of hot parts and specially parts of the
exhaust system.
• If the generating set is unsafe, fit danger notices
and disconnect the battery positive (+) lead so
that it cannot be started until the condition is cor-
rected.
• Do not attempt to operate the generating set with
a known unsafe condition. Disconnect the battery
positive (+) lead prior to attempting any repairs or
cleaning inside the enclosure.
• Always consult the manual before carrying out
maintenance.
• Do not change the settings without consulting the
manufacturer. Keep record of changing of the set-
tings in this manual.
2.1.6 Fire and explosion
Fuels can be flammable. Proper handling
limits the risk of fire and explosion.
• Avoid refilling the fuel tank while the engine is
running. When oil or fuel is leaking do not use the
generating set.
• Do not run the engine close to explosives or
gases.
• Hydrogen gas generated by charging batteries is
explosive. Take measures for proper ventilation.
Do not smoke or allow sparks, flames, or other
sources of ignition around batteries.
• Keep a fire extinguisher on hand.
• Poor electrical connections or using wiring which
is not suited for the rated currents can cause
overheating and possibly fire.
2.1.7 Chemicals
• Fuels, oils, coolants, and battery electrolyte can
be hazardous to personnel if not treated properly.
Do not swallow or have skin contact with these
liquids. Do not wear clothing that has been conta-
minated by fuel or lubricating oil.
• Gaskets may be manufactured from asbestos.
CO

8July 2004 / WHISPER 6 ULTRA Mobile / EN
INFORMATION
Particles of this material should not be inhaled as
this may result in fatal diseases.
• On no account allow any unprotected skin to
come into contact with the injector spray as the
fuel may enter the blood stream with fatal results.
• Engines may be fitted with seals or O-rings
manufactured from "viton" or similar material.
When exposed to abnormal high temperatures in
excess of 400ºC 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.
2.2 TRANSPORT, LIFTING AND STORAGE
When lifting the generating set avoid any
risk for personal injuries, do not stand un-
der the generating set.
• Use soft slings to avoid damage.
• On the engine are two lifting eyes, only to be
used to take the generator out of the capsule. Do
not use to lift the set including the capsule and
certainly not including the steel foundation plate !
• After transporting the generating set check for
damage before installation.
• Long term storage can have detrimental effects
on engine and alternator. The engine should be
put through an engine preservation procedure.
(Refer to the maintenance chapter)
• The alternator windings tend to condense. To mi-
nimise condensation, store the generating set in a
dry and warm storage area.
• 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.
2.3 THE WHISPER 6 ULTRA
2.3.1 Features
This generating set includes a diesel engine which is
connected by close coupling to an alternator in a sound
attenuated capsule. The set is mounted on a steel base
frame and mounted securely on anti vibration mounting
pads to the capsule base. All cables and hoses are gui-
ded through the capsule’s sides. The set is not self con-
tained and is only operable after proper installation using
additional accessories and installation materials.
Installation accessories are listed in the installation ma-
nual and are available through the supplier of the genera-
ting set. The full automatic Digital Control is based on
microprocessor technology. Several automatic start/stop
functions can be programmed and monitored. (refer to
Digital Diesel Control users manual)
2.3.2 Remote control
The full automatic remote control panel including 15 mtr
cable comes as standard with the Wisper 16.
2.3.3 Documentation
Included in the delivery is this users manual (number:
50200129) an installation manual (number: 50200369)
and a users manual for DDC (number: 50200361).
Not included in the standard delivery but available as an
option are:
• Parts manual; number: 50200382
• Workshop manual; number: 50200171
However in this manual there is a list of important parts
for maintenance and spare parts as well as a chapter on
maintenance and problem solving.

EN / WHISPER 6 ULTRA Mobile / July 2004 9
INFORMATION
2
3
48
9
18
1617 36 22 38
37
11
20
24
18
35
30
32
31
29
26
5 33 25 1 28 21
19
20
24
18
17
35
23
3627181638
14 15
7
121234
13
6
39
40
41
42
11
43
Fig. 2: Overview Whisper 6 ULTRA.
2.4 COMPONENTS
2.4.1 Main components to identify
1 Air inlet;
2 Starter motor;
3 Battery connection ( negative);
4 Battery connection ( positive);
5 AC 230V wiring;
6 AC 230V output connection box;
7 Fuel filter;
8 Fuel pipe inlet;
9 Fuel pipe return;
10 Bypass hose air vent;
11 Cooling connections;
12 Exhaust manifold (water cooled);
13 Thermo-switch alternator;
14 Injector 3x;
15 Glowplug 3x;
16 Valve cover;
17 Circulation pump engine cooling;
18 Filling cap oil 2x;
19 Solenoid;
20 Electric fuel lift pump;
21 Water pump alternator cooling;
22 Cooling liquid temperature switch;
23 Fuel pressure pump
24 Oil pressure switch;
25 Oil sump pump;
26 Exhaust connection;
27 Fuel vent screw;
28 Oil level indicator;
29 Control panel;
30 Capacitors /
optional voltage regulator;
31 Fuse 2;
32 Fuse 1;
33 Remote control cable;
34 Cooled exhaust bent;
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

10 July 2004 / WHISPER 6 ULTRA Mobile / EN
INFORMATION
2.4.2 Generator control panel
1 Fuse 10A;
2 Fuse 3A;
3 Start/stop button.
2.4.3 Remote control panel
1 Start button;
2 Stop button;
3 Select button;
4 Set button;
5 Failure lamp;
6 Generator load indicator.
7 Display
2.5 TECHNICAL INFORMATION
2.5.1 AC alternator
The single phase synchronous alternator is directly
coupled, one bearing, brushless, rotating field design,
four pole (1500 RPM) and self regulating.
Residual magnetism causes a small voltage over the sta-
tor windings and allows a current to flow in the windings,
which is magnified because of the feed back effect be-
tween rotor and stator. The field windings in the rotor are
short-circuited over a diode to rectify the current. A capa-
citor over an additional winding in the stator which is in
an angle with the power-winding keeps the voltage stable
within 5% at the specified rpm and provides voltage fall
off with speed, preventing over-excitation at low engine
speeds and softening the effect of load switching to
relieve the burden on the engine.
Further technical data on the design of the alternator can
be found in drawings and diagrams in this manual. The
alternator is watercooled and the cooling liquid is cooled
by a radiator.
2.5.2 Engine
The Whisper generating set is based on the Mitsubishi L3E
3 cylinder diesel engine. The engine is indirectly injected.
The engine is water cooled and the cooling liquid is cooled
by a radiator.The engine has been specially adapted for the
Mastervolt application and is very different from the
standard engine as supplied for industrial applications!
2.5.3 Digital Diesel Control system
The standard electrical engine control system is 12 Volt
negative earth, non earth return is available as optional.
Check your identification data to determine which system
is applied. The system is designed according to the
"energise to run" system. The Digital Diesel Control is a
very advanced microprocessor based full automatic
system. Besides automatic start the system offers many
monitoring options. Refer to the separate Digital Diesel
Control users manual.
The microprocessor unit is located on top of the alternator.
2.5.4 Battery charger
On the engine is an alternator generating 50 Amp 12V.
This current is rectified to charge the battery. The
voltage is regulated at 14.2V.
2.5.5 Alarms and shut down
In the event of malfunctioning this will be indicated by the
External Fuel Pump
Protection-fuse
10 A
Digital Diesel Control
Protection-fuse 3 A
Remove fuse
during maintenance
Whisper Generator Control
Press for start/stop
3 A 3 A
123
Fig. 5: Digital Diesel remote control panel.
Fig.. 3: Control panel.
hold gnd tem str. exh oil reg alt. fuel
heat start fuel fail
st
gl
+
pull
ct-2 ct-1 ct-1 ct-2
AC-1
AC-2
Fig.. 4: Digital Diesel Control unit
61 2
74 3
5

EN / WHISPER 6 ULTRA Mobile / July 2004 11
INFORMATION
failure light and detail will be shown on the display the
engine will be shut down. There are three functions
guarded: oil pressure, coolant temperature and alternator
temperature. Exhaust temperature too high indicates the
alternator cooling water to be blocked. All alarm switches
are closed when no malfunction occurs. A contact is cut
in the event of an alarm. This means that the generating
set will not work when the alarm switches are broken or
there is a loose wire. The system therefore is intrinsically
safe. The panel will display details about the alarm.
2.5.6 Control
The generating set can be operated by push buttons on
the panel on the alternator or by the remote control. By
pushing the START button the control system is activated
and will start the engine automatically. Pushing the
STOP button will stop the engine and the electrical
system will be deactivated. Stopping the engine is
executed by the fuel valve solenoid that will shut off.
2.5.7 Remote control
All wiring connections from the remote control to the
board are made by plug in connectors.An intermediate
communication cable is in the standard supply. If neces-
sary an optional longer 8 wire twisted cable can be
connected if the standard length does not suit the requi-
red distance. Numerous remote control units can be put
in parallel by using the connectors on the back of the
units. (Refer to installation instructions)
2.5.8 Hour counter
The remote control offers several timer functions and
helps to schedule maintenance.
2.5.9 Load indicator
On the remote control the load will be indicated on the
display and by the LEDbar. The load is measured by
current transformers on the alternator.
2.5.10 Fuel specification
The engine must only be used with diesel fuel oil which
conforms to the standards for use in modern diesel en-
gines. Fuel free from water and contaminants is of the ut-
most importance.
2.5.11 Oil information
1 Specification:
The oil must be suitable for oil changes as specified
in the maintenance chapter. The Mitsubishi engine
must be run on heavy duty lubricating oil meeting the
requirements of API class CC or CD.
It is very important to use the correct oil
specification. Very often local oil suppliers
recommend a higher class, because they
assume that a higher class is allowed. This
is not the case. One should not follow
these recommendations.
Using the wrong specification will cause
high oil consumption.
2 Oil viscosity:
We recommend a multigrade oil 10W40.
3 Oil capacity:
Excluding the oil filter the content of the crankcase is
3,6 l. Including the oil filter it is 4,1 l.
Do not overfill with lubricating oil as this may have a
detrimental effect on engine performance.
4 Oil pressure
• Minimum at idle 98 Kpa (1 kgf/cm2/14psi)(1 bar).
• Normal at 1500 rpm ±250 Kpa (2,5 kgf/cm2/ 35
psi)(2,5 bar).
2.5.12 Cooling liquid
The engine and alternator are cooled by cooling liquid.
The capacity of both systems depend on the capacity of
the radiator piping and other parts of the cooling system.
We recommend not using water but cooling liquid that is
marketed for the use in combustion engines. Cooling
liquid protects the engine against frost to minus 25° C.
Also it protects the engine block against corrosion.
Initially one can fill the engine via the filling cap on the
exhaust manifold. Fill up till the level is just below the
filling cap. Filling of the alternator cooling system and
additional filling of engine cooling system has to be done
via the expansion tanks. When the engine is on
temperature the liquid will expand and the redundant
liquid will be pressed into the expansion tank. This tank
has to be filled up to the mark. On the tank is an overflow
connection. This should be open hose can be connected
to drain the overflow to outside the vehicle. When cooling
liquid is not available clean fresh water could be used
with an additive of anti freeze. When using water with
anti freeze the right mixture has to be cal-culated
according to the information of the supplier of the anti
freeze. The cooling system is not pressurised. There
should be a special cap on the engine manifold without
valves leaving the connection to the expansion tank
open.

12 July 2004 / WHISPER 6 ULTRA Mobile / EN
INFORMATION
2.5.13 Technical data
GENERAL
Model WHISPER 6 ULTRA
RPM 1500 rpm
Alternator water cooled, synchronous
Engine Mitsubishi diesel, model L3E (Japan)
Number of cylinders 3
Displacement 952 cm3
Bore X stroke 76x70 mm
Combustion air consumption 0.9 m3/min.
Continuous power 50Hz 5,7 kW
Cooling system by radiator
Fuel lift pump engine electric pump (12 V DC), additional pump available upon request
Starting battery (optional) 60-90 Ah12V
Fuel consumption 1.5-2,5 litre/hour, load dependent
Enaine control Digital Diesel Control
ELECTRICAL SPECIFICATIONS
Output voltage 230V 50 Hz alternating current (AC) single phase
Output rating 50Hz (ULTRA) 5,7 kW at power factor cos phi = 1
Voltage tolerance ± 5% (optional voltage regulator 2%)
Frequency tolerance ± 5%
Optional electronic Governor ± 1%
Alternator brushless, four pole, synchronous
Voltage regulation capacitor (AVR optional)
MECHANICAL SPECIFICATIONS
Supply includes generating set, built into tugged GRP sound shield with steel base plate,
mounted on rubber anti vibration mounts
Dimensions hxwxd 810x525x615 mm
Colour top white, bottom green
Weight 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

EN / WHISPER 6 ULTRA Mobile / July 2004 13
INFORMATION
2.5.14 Wiring codes and colours
Cable code number colour cross section
STANDARD
battery > starter motor red 25 mm2
starter motor > DDC 1 red 6 mm2
starter motor > LCP 13 red 2,5 mm2
battery > ground black 25 mm2
ground > LCP ground (GND) 2 black 4 mm2
DDC > glow plugs 3 brown 4 mm2
DDC > starter solenoid 4 yellow 2,5 mm2
LCP > fuel lift pump + 5 brown 1,5 mm2
LCP > fuel lift pump - 15 black 1,5 mm2
DDC > LCD 5 grey 1,5 mm2
DDC > oil pressure switch 6 purple 1 mm2
LCP > oil pressure switch 6 purple/black 1 mm2
DDC > water temperature switch 7 blue 1 mm2
LCP > water temperature switch 7 blue/black 1 mm2
DDC > exhaust temperature switch 8 blue/green 1 mm2
LCP > exhaust temperature switch 8 blue/rose 1 mm2
DDC > fuel solenoid (hold) 9 green 1,5 mm2
DDC > fuel solenoid (pull) 20 pink 1,5 mm2
DDC > fuel solenoid (com.) 17 black 1,5 mm2
B+ terminal alternator > starter motor 21 red 6 mm2
DDC > R terminal alternator 18 wit 1,5 mm2
DDC > L terminal alternator 19 orange 1,5 mm2
DDC > current measuring transformer 11 black 1 mm2
DDC > current measuring transformer 11 red 1 mm2
DDC > LCP 12 black 1,5 mm2
DDC > LCP 14 red 1,5 mm2
DDC > LCP 16 red/green 1,5 mm2
DDC > generator AC output 33 brown 1 mm2
DDC > generator AC output 33 blue 1 mm2
DDC=Digital Diesel Control Unit
LCP=Local Control Panel

14 July 2004 / WHISPER 6 ULTRA Mobile / EN
INFORMATION
2.5.15a Lay out control wiring 230V AC Radiator fan
hold
ct-2
ct-1
ct-1
ct-2
gnd
tem
str.
exh
oil
reg
alt.
fuel
heat start fuel fail
st
gl
+
pull
AC-1 AC-2
LOCAL CONTROL PANEL
MM
J28
3xPUMP OUTPUT
ALT
J1
ALT
J2
REGULATOR
J22
START/STOP
J8 J9
-
J10
-
J11
J12
-
-
J13
- -
J14 J16
-
J15 J17
-
WCH/1
--
TAILOR MADE ENERGY
ALT-L
J3
J4 J6
+
J5 J7
+
MASTERVOLT
+
+
3A 3A
F3
10A
ALT
J24 J21 J23 J19 J18
SOLENOID
FUEL
WHITE (HOLD)
BLUE (COM.)
RED (PULL)
BATTERY
RED 25
12VDC
RED 2,5 (1)
BLACK 25
GROUND TO
BLACK 4 (2)J17
WATER TEMP.
SWITCH
GENERATOR TEMP.
SWITCH
OIL PRESS.
SWITCH
MOTOR
STARTER
CURRENT MESURING
TRANSFORMER
BLUE 1 (7)
BLUE/GREEN 1 (8)
BLUE/BLACK 1 (7) J10
BLACK 1,5 (12) J8
BLUE/PINK 1 (8) J12
PURPLE 1 (6)
PURPLE/BLACK 1 (6) J14
BLACK 2,5 (17) J16
GREY 1,5 (5)
BLACK (11)
RED (11)
YELLOW 2,5 (4)
RED/GREEN 1 (16)
R
B
L
P
ALTERNATOR
RED 6 (21)
ORANGE 1,5 (19)
GREEN 1,5 (9)
GREY 2,5 (20)
RED 1,5 (14)
WHITE 1,5 (18)
ENGINE BLOCK
(OPIONAL) (OPTIONAL)
BATTERY
SWITCH
AC-1
TO GENERATOR AC OUTPUT
BLUE (33)
BROWN (33)
CONTROL PANEL TO REMOTE
BLACK 1,5 (23) J15
AIR FAN 1 AIR FAN 2
BLACK 1,5 (32) J11
230VAC
TO CONNECT BEFORE
FUSES AND BREAKERS
GENERATOR
THERMOSTAT
JUNCTIONBOX AIR FAN
+-
FUEL LIFT
PUMP
GREY 1,5 (5)
BROWN 1,5 (31)
RED 2,5 (13)
GLOW (PREHEAT)
PLUGS
BROWN 4 (3)
Fig. 7: Lay out control PCB.

EN / WHISPER 6 ULTRA Mobile / July 2004 15
hold
ct-2
ct-1
ct-1
ct-2
gnd
tem
str.
exh
oil
reg
alt.
fuel
heat start fuel fail
st
gl
+
pull
AC-1 AC-2
LOCAL CONTROL PANEL
MM
J28
3xPUMP OUTPUT
ALT
J1
ALT
J2
REGULATOR
J22
START/STOP
J8 J9
-
J10
-
J11
J12
- -
J13
- -
J14 J16
-
J15 J17
-
WCH/1
--
TAILOR MADE ENERGY
ALT-L
J3
J4 J6
+
J5 J7
+
MASTERVOLT
+
+
3A 3A
F3
10A
ALT
J24 J21 J23 J19 J18
SOLENOID
FUEL
WHITE (HOLD)
BLUE (COM.)
RED (PULL)
BATTERY
RED 25
12VDC
RED 2,5 (1)
BLACK 25
GROUND TO
BLACK 4 (2)J17
WATER TEMP.
SWITCH
GENERATOR TEMP.
SWITCH
OIL PRESS.
SWITCH
MOTOR
STARTER
CURRENT MESURING
TRANSFORMER
BLUE 1 (7)
BLUE/GREEN 1 (8)
BLUE/BLACK 1 (7) J10
BLACK 1,5 (12) J8
BLUE/PINK 1 (8) J12
PURPLE 1 (6)
PURPLE/BLACK 1 (6) J14
BLACK 2,5 (17) J16
GREY 1,5 (5)
BLACK (11)
RED (11)
YELLOW 2,5 (4)
RED/GREEN 1 (16)
R
B
L
P
ALTERNATOR
RED 6 (21)
ORANGE 1,5 (19)
GREEN 1,5 (9)
GREY 2,5 (20)
RED 1,5 (14)
WHITE 1,5 (18)
ENGINE BLOCK
(OPIONAL) (OPTIONAL)
BATTERY
SWITCH
AC-1
TO GENERATOR AC OUTPUT
BLUE (33)
BROWN (33)
CONTROL PANEL TO REMOTE
BLACK 1,5 (23) J15
AIR FAN 1 AIR FAN 2
BLACK 1,5 (32) J11
THERMOSTAT
JUNCTIONBOX AIR FAN
+-
FUEL LIFT
PUMP
GREY 1,5 (5)
BROWN 1,5 (31)
RED 2,5 (13)
GLOW (PREHEAT)
PLUGS
BROWN 4 (3)
230VAC (110VAC)
IVO
(OPTIONAL)
CHARGER
BATTERY
24VDC
(OPIONAL) (OPTIONAL)
CHARGER
IVO
230VAC (110VAC)
BATTERY
SWITCH
(OPTIONAL)
GROUND
BLACK 4
RED 4
2.5.15b Lay out control PCB 24V DC radiator fan

16 July 2004 / WHISPER 6 ULTRA Mobile / EN
hold
ct-2
ct-1
ct-1
ct-2
gnd
tem
str.
exh
oil
reg
alt.
fuel
heat start fuel fail
st
gl
+
pull
AC-1 AC-2
LOCAL CONTROL PANEL
MM
J28
3xPUMP OUTPUT
ALT
J1
ALT
J2
REGULATOR
J22
START/STOP
J8 J9
-
J10
-
J11
J12
- -
J13
- -
J14 J16
-
J15 J17
-
WCH/1
--
TAILOR MADE ENERGY
ALT-L
J3
J4 J6
+
J5 J7
+
MASTERVOLT
+
+
3A 3A
F3
10A
ALT
J24 J21 J23 J19 J18
SOLENOID
FUEL
WHITE (HOLD)
BLUE (COM.)
RED (PULL)
BATTERY
RED 25
12VDC
RED 2,5 (1)
BLACK 25
GROUND TO
BLACK 4 (2)J17
WATER TEMP.
SWITCH
GENERATOR TEMP.
SWITCH
OIL PRESS.
SWITCH
MOTOR
STARTER
CURRENT MESURING
TRANSFORMER
BLUE 1 (7)
BLUE/GREEN 1 (8)
BLUE/BLACK 1 (7) J10
BLACK 1,5 (12) J8
BLUE/PINK 1 (8) J12
PURPLE 1 (6)
PURPLE/BLACK 1 (6) J14
BLACK 2,5 (17) J16
GREY 1,5 (5)
BLACK (11)
RED (11)
YELLOW 2,5 (4)
RED/GREEN 1 (16)
R
B
L
P
ALTERNATOR
RED 6 (21)
ORANGE 1,5 (19)
GREEN 1,5 (9)
GREY 2,5 (20)
RED 1,5 (14)
WHITE 1,5 (18)
ENGINE BLOCK
(OPIONAL) (OPTIONAL)
BATTERY
SWITCH
AC-1
TO GENERATOR AC OUTPUT
BLUE (33)
BROWN (33)
CONTROL PANEL TO REMOTE
BLACK 1,5 (23) J15
AIR FAN 1 AIR FAN 2
BLACK 1,5 (32) J11
THERMOSTAT
JUNCTIONBOX AIR FAN
+-
FUEL LIFT
PUMP
GREY 1,5 (5)
BROWN 1,5 (31)
RED 2,5 (13)
GLOW (PREHEAT)
PLUGS
BROWN 4 (3)
230VAC (110VAC)
IVO
(OPTIONAL)
CHARGER
RED 4
BLACK 4
2.5.15c Lay out control PCB 12V DC radiator fan

EN / WHISPER 6 ULTRA Mobile / July 2004 17
2.5.16 Electrical diagram 230V 50Hz
INFORMATION
ROTOR
STATOR
PE
N
230V 50Hz
L1
230V 50Hz
EARTH AND NEUTRAL CONNECTED
N
PE
L1
EARTH AND NEUTRAL
NOT CONNECTED
MAIN WINDING
(4)
(4)
(3)
MAIN WINDING
(2)
(3)
EXCITATION
(1)
WINDING
YELLOW/GREEN
DCC/AC-1
YELLOW/GREEN
BLUE (33) BROWN (33)
BLUE
DCC/ct-1
(11)
RED
CURRENT
TRANSFORMER
(11)
BLACK
CAPACITOR
BROWN
DCC/ct-1
(11)
RED
TRANSFORMER
(11)
BLACK
CURRENT
DCC/AC-1
YELLOW/GREEN
BLUE
YELLOW/GREEN
BROWN
BROWN (33) BLUE (33)

2.5.17a Diagram fan control 230V
18 July 2004 / WHISPER 6 ULTRA Mobile / EN
INFORMATION
TERMINAL BLOCK
GENERATOR CONTACT PUMP (PCB)
THERMOSTAT GENERATOR THERMOSTAT ENGINE
RADIATOR COOLER
GENERATOR
BATTERY
230VAC
ENGINE
- 12V
THERMOSTAT COOLER
PUMP
+12V
BAT. GENERATOR
FUSE 6,3A
230VAC (N)
FUSE 5A
BAT.
+12V 230VAC (L1)
GENERATOR
FUSE 6,3A
RADIATOR COOLER GENERATOR
GENERATOR
RADIATOR COOLERRADIATOR COOLER
ENGINE
FUSE 5A FUSE 5
A
POWER SUPPLY 230 VAC
ENGINE GENERATOR
DIMENTION BOX: 270x270x180 MM
JUNCTION BOX AIR FANS
12VDC
M
230VAC
M
MM
MM
12VDC K1 K2
230/115VAC
200VA
TRAFO
230VAC
230VAC
5A
16
230V
400V
CU1,5
+
1
-
2
CU0,75
80-70?C
CU0,75
45-35?C
CU0,75
6
-
3
5A
45 87
CU1,5
230VAC
CU1.5
6,3A
11
6,3A
12 1413 15
5A
2
A1
A2
K1
1
3
A2
A1
K2
45-35?C80-70?C
7
5
8
6
12
41
44
K1
11
4
11
14
K1
CU1.5
230VAC
44
42
41
K2
TRAFO
200VA
230/115VAC
0
110V
0
120V
115V
K2
14
12
11
13
15
230VAC
14
16
BREAKER
CIRCUIT
AIRFAN
L1
N
GENERATOR
6A
AIRFAN
BREAKER
CIRCUIT
MAIN

EN / WHISPER 6 ULTRA Mobile / July 2004 19
PUMP (PCB) GENERATOR CONTACT THERMOSTAT ALTERNATOR THERMOSTAT ENGINE ALTERNATOR RADIATOR COOLER
RADIATOR COOLER
ENGINE
BATTERY
TERMINAL BLOCK
THERMOSTAT COOLER
ALTERNATOR
+ BAT.
FUSE
JUCTION BOX AIR FANS
FUSE
CONTROL PANEL
RADIATOR COOLER
ALTERNATOR
PUMP 2 - BAT.
ENGINE ENGINE
M
M
M
M
M
M
M
M
-
+
CU0,75
80-70∞C
CU4 CU0,75
45-35∞C
CU0,75
+
4
+
1
-
2
-
356
+
7
CU2,5
CU2.5
-
8
+
9
-
10
1
2
K1
80-70∞C
5
6
K2
1
2
5
45-35∞C
3
5
3
20/40A
1
20/40A
K3
21435768
K1
10
9
K2
K1
4
10
-
+
9
5
8
3
7
K2
3
2
1
K3
42
K3
DIMENIONS BOX: 160x160x90 MM
2.5.17b Diagram fan control 12V / 24V

20 July 2004 / WHISPER 6 ULTRA Mobile / EN
OPERATION
3 OPERATION
3.1 GENERAL
The generating set is operational after full installation and
filling up with: fuel, engine lubricating oil and cooling li-
quid, filling the starter battery with acid, and connecting
the battery to earth.
3.2 OPERATION INSTRUCTIONS
3.2.1 Summarised operating instructions (daily use)
Routine "pre-start" checks:
1 Check oil level (refer to fig. 10).
2 Check cooling system (coolant levels).
3 Power source selector switch (off/shore power/gene-
rator power). Switch to power source switch "OFF", or
switch off all consumers in the usual way. If a MAS-
TERSWITCH is installed, this is operating automati-
cally.
4 Switch on battery switch (when installed).
5 Fuel valve: open.
Starting:
Push the start button to initiate the full automatic
starting procedure. You can monitor the procedure on
the display.
In operation checks:
1 Check for abnormal noise or vibration
2 Check the voltage
3 Power source selector switch (off/shore power/gene-
rator power). Switch to power source generator. If a
MASTERSWITCH is installed, this is operating auto-
matically.
4 Before loading the generating set up to maximum,
have it run warm. Continuous load should be restric-
ted to 70 % of maximum load.
Stopping generator:
1 Switch off all electrical devices (consumers). If the
generating set has been running under full load for a
longer period, do not shut it down abruptly. Reduce
the electrical load to about 30% of the rated load and
let it run for approx. 5 minutes.
2 Press the STOP button.
3 Switch to another 230V power source, if available. If
a Masterswitch is installed, this is done automatically.
3.2.2 Extended operating instructions
Check when starting the first time or after a longer period
of rest:
1 If there is any damage caused by transport or instal-
lation.
2 Check if installation conforms with the installation
instructions.
3 Ensure the generating set is free to turn without ob-
struction.
4 Check all hoses and hose connections for leaks.
5 Check all cables and cable end terminal connections.
6 Check the engine and generator mounting bolts.
Routine "pre-start" checks:
1 Check engine oil level.
The generator switches off in the event of insufficient
oil-pressure. Even when the oil level is too low the oil
pressure can be high enough. Do not run the
generator with the oil below the lowest mark, because
a smaller volume of oil will become contaminated
considerably quicker than a larger volume. Therefore
we recommend daily oil-checks.
Check oil level prior to starting the engine, or at least
5 minutes after the engine has stopped.
2 Check coolant in both expansion tanks
3 Check for leakage’s.
4 If no MASTERSWITCH is used: Switch main Power
Source Selector switch to "OFF" or switch off all de-
vices.
5 Switch on the battery switch.
1
2
Fig. 10.
1 Max. oil level;
2 Min. oil level.