Mastervolt Whisper 6 User manual

MASTERVOLT
Snijdersbergweg 93
1105 AN Amsterdam
The Netherlands
Tel.: [phone]
Fax: [phone]
www.mastervolt.com
USERS MANUAL U.S.A. EDITION
V1. April 2004
WHISPER 6 / 8 / 12
-3600 RPM-
Marine diesel generating set 120V/240V-60Hz
Digital Diesel Control
Art.no. 50200354

2April 2004 / WHISPER 6/8/12 / U.S.A.EDITION
CONTENTS
CONTENTS
1INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.2 Service and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.3 Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.4 Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.5 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.5.2 Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2.1.2 Electrical safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2.1.3 Earth insulation failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
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 6/8/12 generating set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
2.3.1 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
2.3.2 Remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
2.3.3 Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
2.3.4 Accesories included in the stanbdard delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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 Digital diesel control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
2.5.4 Battery charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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
This manual applies to the Mastervolt Whisper 6, 8, 12 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

U.S.A.EDITION / WHISPER 6/8/12 / April 2004 3
2.5.12 Cooling liquid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
2.5.13 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
2.5.14 Wiring, codes and colours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
2.5.15 Lay out control PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
2.5.16 Electrical diagram 120/240V AC 60Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
2.5.17 Diagram electronic governor (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
3OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
3.2 Operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
3.2.1 Summarised operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
3.2.2 Extended operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
4MAINTENANCE AND CARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
4.1 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
4.2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
4.2.1 General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
4.2.2 Bleeding fuel lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
4.2.3 Valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
4.2.4 Replacing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
4.2.5 Replacing the oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
4.2.6 Readjusting V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
4.3 Regular maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
4.3.1 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
4.3.2 Putting out of service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
5TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
5.1 Alternator malfucntions / AC trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
5.1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
5.1.2 Trouble shooting check list alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
5.2 Engine malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
5.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
5.2.2 Trouble shooting check list engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
5.2.3 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
5.2.4 Service address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
5.3 Special procedures alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
5.3.1 Residual voltage check / excitation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
5.3.2 Testing rotary diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
5.3.3 Windings resistance values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
5.3.4 Meggering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
5.4 Special procedures engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
5.4.1 Readjusting RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
5.4.2 Valve clearance / retightening cylinder head bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
5.4.3 Measuring exhaust backpressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
5.4.4 Disassembly instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
6SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
7MAINTENANCE LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
CONTENTS

4April 2004 / WHISPER 6/8/12 / U.S.A.EDITION
INTRODUCTION
1 INTRODUCTION
1.1 GENERAL
The Whisper 6/8/12 Marine Diesel Generating set is ma-
nufactured 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 well 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:
Awarning 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.
1.2 SERVICE AND MAINTENANCE
Regular service and maintenance should be executed
according 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. For USA deliveries there are
additional conditions. These are available at
MASTERVOLT USA. 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, neglect or a faulty installation.
Example 1. Faulty installation:
Seawater entering the engine is the most common cause of
damage to combustion engines in boats. (Both to propulsion
and generator engines.) The entry of water must be avoided
under all conditions. Be aware that the conditions in blue
water sailing can be extreme. Refer to the installation
manual for instructions but remember these are for
guidance only as many factors influence the installation of a
generator. The ultimate responsibility will always be with the
owner to ensure a safe and compliant installation.
DAMAGE CAUSED BY THE INGRESS
OF WATER IS NEVER COVERED BY
WARRANTEE.
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
Sometimes the seal of the raw water pump starts leaking.
Mostly this begins with a little drip and slowly gets worse.
Regular visual inspection of the generator is necessary to
prevent damage to occur from a leaking water pump.
When one find serious damage after weeks of neglect
warrantee claims will not be honoured.
Example 4: Neglect
Whisper generators have an option for an auto start/stop
mode or interval mode.

U.S.A.EDITION / WHISPER 6/8/12 / April 2004 5
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
board a vessel 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 boat or for reinstallation. There is no cover for labour
needed to get access to the generator, for example to
remove equipment or bulkheads etc. Refer to
MASTERVOLT USA
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 seawater, 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.
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.
1The identity of the generating set is given by the SE-
RIAL NUMBER.
660x495x550 mm
25 A / 50 A
6 KVA cos phi = 1
50902055
Whisper 6
178 kg
120 V / 240 V
60 Hz
SINGLE PHASE/DUAL VOLTAGE PHASE
DIMENSIONS
WxDxH 26" x 19,5" x 21,7"
WEIGHT
ARTICLE NO
MODEL
SERIAL NUMBER
MAX. POWER
VOLTAGE
FREQUENCY
CURRENT
Fig. 1: Nameplate.
INTRODUCTION

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 has 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 gasses etc.
2.1.2 Electrical safety
The voltage of 120/240 Volt generated by
this generating set is dangerous and if in-
structions and procedures are not strictly
observed may result in electrical shock
which will result in severe personal injury
or loss of life.
•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.
6April 2004 / WHISPER 6/8/12 / U.S.A.EDITION
INFORMATION
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:
2POWER
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.
The power should never exceed the nominal Power
in kW as shown on the nameplate. Power is rated at
an ambient temperature of 104°F (40°C) and a sea-
water temperature of 77°F (25°C). For higher
temperatures the generating set has to be derated.
3VOLTAGE shows the nominal voltage.
This voltage should be within the specified tolerance
at the nominal frequency.
4FREQUENCY is shown in Hz and is determined by
the speed of the engine (RPM). 60 Hz correlates with
3600 rpm.
5CURRENT shows the maximum current that is ac-
ceptable at the specified frequency, voltage and po-
wer factor.
6WEIGHT shows the net dry weight (approximately) in
kg. This is without fuel, oil, cooling liquid, packing and
external installation equipment.
7The 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
circumstances. See also the remarks in this manual
under SAFETY
8Exhaust emission of the engines used in this
generating set is according EPA regulations and the
engines are certified and labeled as such by the
manufacturer.
Before changing a factory setting you are advised to consult
the manufacturer. When the generating set you have to
identify is not new you have to take into account the
possibility that former users did change the settings. Check
the settings (voltage, frequency, rpm) when any doubt.

U.S.A.EDITION / WHISPER 6/8/12 / April 2004 7
2.1.3 Earth insulation failures
According to local regulations and depending on the ap-
plication it is necessary to take measures for protection
against earth insulation failures. In the U.S.A. version
neutral and ground are connected on the alternator. This
requires an insulation protection device as commonly
used in the U.S.A. This installation is beyond the
influence of Mastervolt and Mastervolt cannot held
responsible for any consequence as a result of the
installation.
In all situations the transfer switches
between shore, inverter and generator
should switch both neutral and line.
Ofcourse 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 such as a machine room. Installation
includes measures to be taken to outlet exhaust fumes
which contains carbon monoxide and are extremely
dangerous. Carbon monoxide (CO) is an invisible
odorless 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.
2.1.5 Operation
External moving parts like fans and V-belts are covered
by the canopy and therefore the Whisper 7000 ULTRA is
very safe, when the canopy is closed
Never the less 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 executing
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
gasses.
•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.
Particles of this material should not be inhaled as
this may result in fatal diseases.
INFORMATION
CO

8April 2004 / WHISPER 6/8/12 / U.S.A.EDITION
INFORMATION
•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 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.
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 6/8/12
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 45 ft.
(15 mtr) cable comes as standard with the Wisper 6, 8,
12.
2.3.3 Documentation
Included in the delivery is this users manual (number:
50200354) an installation manual (number: 50200364)
and a users manual for DCC (number: 50200261).
Not included in the standard delivery but available as an
option are:
• Parts manual; number: 50200381 (6, 8)
• Parts manual; number: 50200382 (12)
• Workshop manual; number: 50200171 (6, 8, 12)
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.
2.3.4 Accessories included in the standard delivery
•Special hoseconnector for measuring exhaust
backpressure
•Expansion tank, hose and fittings

U.S.A.EDITION / WHISPER 6/8/12 / April 2004 9
2
3
48
9
10
18
1617 36 22 38
37
11
20
24
18
35
30
32
31
29
26
533 25 1 28 21
19
20
24
18
17
35
23
3627181638
14 15
7
121234136
39
40
41
42
10
11
43
Fig. 2: Overview Whisper 6/8.
INFORMATION
6/8 12
2.4 COMPONENTS
2.4.1 Main components to identify
1Air inlet;
2Starter motor;
3Battery connection ( negative);
4Battery connection ( positive);
5AC wiring;
6AC output connection box;
7Fuel filter;
8Fuel pipe inlet;
9Fuel pipe return;
10 Bypass hose air vent;
11 Cooling water in;
12 Exhaust manifold (water cooled);
13 Thermo-switch exhaust;
14 Injector (6/8 2x )(12 3x);
15 Glow plug (6/8 2x) (12 3x);
16 Valve cover;
17 Circulation pump;
18 Filling cap oil 2x;
19 Solenoid;
20 Electric fuel lift pump;
21 Raw water pump;
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 8/12);
31 Fuse 1;
32 Fuse 2;
33 Remote control cable;
34 Cooling water injection;
35 RPM adjustment screw;
36 Thermostat housing;
37 Alternator;
38 Filling cap coolant;
39 Heat exchanger;
40 Drain plug coolant;
41 Stop lever;
42 Oil filter.
43 Digital Diesel Control

10 April 2004 / WHISPER 6/8/12 / U.S.A.EDITION
INFORMATION
2.4.2 Generator control panel
1Fuse 10A;
2Fuse 3A;
3Start/stop button.
2.4.3 Remote control panel
1Start button;
2Stop button;
3Select button;
4Set button;
5Failure lamp;
6Generator load indicator.
7Display
2.5 TECHNICAL INFORMATION
2.5.1 AC alternator
The single phase alternator is directly coupled, one bea-
ring, brushless, rotating field design, two pole (3600
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.
2.5.2 Engine
The Whisper 6/8 generating set is based on the
Mitsubishi L2E 2 cylinder diesel engine. The Whisper 12
on the L3E 3 cylinder. The engine is indirectly injected.
The engine is water cooled and the cooling liquid is
cooled by a heat exchanger and raw water. The heat
exchanger and all other parts which are in direct contact
with the raw (sea) water are made of seawater resistant
material like naval brass and gunmetal.
The engine has been specially adapted for the Mastervolt
application and is very different from the standard engine
as supplied for industrial applications! The engine fulfills
EPA emission standards and is certified and labeled as
such.
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.
ExternalFuelPump
Protection-fuse
10A
DigitalDieselControl
Protection-fuse3A
Removefuse
duringmaintenance
WhisperGeneratorControl
Pressforstart/stop
10 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

U.S.A.EDITION / WHISPER 6/8/12 / April 2004 11
2.5.4 Battery charger
On the engine is an alternator generating 40 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 case of malfunctioning this will be indicated by the fai-
lure light and detail will be shown on the display the
engine will be shut down. There are three functions
guarded: oil pressure, oil temperature and exhaust
temperature.
Exhaust temperature too high indicates the cooling water
to be blocked.
All alarm switches are closed when no malfunction
occurs. A contact is cut in case 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 Digital Diesel 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 automaticly. 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 necessary an optional longer 8 wire twisted
cable can be connected if the standard length does not
suit the required 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 a
current transformer on the alternator.
2.5.10 Fuel specification
The engine must only be used with diesel fuel oil which
conforms 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
1Specification:
The oil must be suitable for oil changes as specified
in the maintenance chapter. The engine must be run
on heavy duty lubricating oil meeting the require-
ments 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 this
recommendations.
Using the wrong specification will cause
high oil consumption.
2Oil viscosity:
We recommend a multigrade oil 10W40.
3Oil capacity:
Excluding the oil filter the content of the crankcase of
the Whisper 6/8 is 2,5 U.S. qts (2.4 l); Whisper 12:
3,7 U.S. qts (3,6 l). Including the oil filter it is 3 U.S.
qts (2.9 l); Whisper 12: 4,3 U.S. qts (4,1 l).
Do not overfill with lubricating oil as this may have a
detrimental effect on engine performance and cause
damage.
4Oil pressure
•Minimum at idle 98 Kpa (1 kgf/cm2-14psi)(1 bar).
•Normal at 3000 rpm ± 300 Kpa (3 kgf/cm2/ 42
psi).
INFORMATION

12 April 2004 / WHISPER 6/8/12 / U.S.A.EDITION
INFORMATION
2.5.13 Technical data
GENERAL
Model WHISPER 6/8/12
RPM 3600
Alternator water cooled, synchronous
Engine Mitsubishi diesel, model L2E (6/8); L3E (12) (Japan)
Number of cylinders 2 (6/8); 3 (12)
Displacement 38,75 cubic inches / 635 cm3(6/8); 58,09 cubic inches / 952 cm3(12)
Bore X stroke 2,99 x 2,76 inches76x70 mm
Combustion air consumption 40 cf/m (1.1 m3/min.) (6/8); 60 cf/m (1,7 m3/min) (12)
Continuous power 60Hz 6 kW (6); 8 kW (8); 12 kW (12)
Cooling system indirect cooling by raw water, 2,6 - 3,5 U.S. qpm / 10-14 l/min.
Cooling water pump pto driven Mastervolt self priming impeller pump, type M
Fuel lift pump engine electric pump (12 V DC), additional pump available upon request
Starting battery (optional) 60-90 Ah12V
Fuel consumption 0,4 - 1 U.S. qph (1.5-4 litre/hour), load dependent
Control Digital Diesel Control including automatic start/stop
ELECTRICAL SPECIFICATIONS
Output voltage 120V or 120/240V 60 Hz alternating current (AC) single phase-dual voltage
Output rating 60Hz 6 kW (6); 8 kW (8); 12 kW (12) at power factor 1
Voltage tolerance ± 5%
Frequency tolerance ± 5%
Optional electronic governor ± 1%
Alternator brushless, two pole, synchronous
Voltage regulation 6: capacitor, 8/12: 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 6/8: 26x37,2x21,65 inches 660x495x550 mm;
12: 31,9x20,61x24,2 inches 810x525x615 mm
Colour top white, bottom green
Weight 6/8:392 lbs (178 kg); 12: 463 lbs (210 kg) including canopy
Max. installation angle 25 degrees
Standard supplies remote panel (45 ft (±15 m) cable), fuel lift pump, expansion tank
Optional installation kits, mobile (vehicle) version, ungrounded, spare part kits
2.5.12 Cooling liquid
The engine is cooled by cooling liquid. The capacity of
this system of the Whisper 6-8 is 2,1 U.S. qts (2 litres)
and of the Whisper 12 3,7 U.S. qts (3,5 litres).
We recommend not using water but cooling liquid that is
marketed for the use in combustion engines. Cooling
liquid protects the engine against frost until minus 77°F
(25° C). Also it protects the engine block against
corrosion. One can fill the engine via the filling cap on the
exhaust manifold. Fill up till the level is just below the
filling cap. 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 till the
mark.
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. When the cooling is based on keel cooling or
radiator cooling the capacity of these coolers and piping
has to be taken into account calculating the right mixture.
The cooling liquid in the engine is pressurised and has a
boiling point above 212°F (100° C). The temperature
switch in the thermostat housing switches at 230°F (110°
C). When keel cooling or radiator cooling is applied the
cooling system is not pressurised. There should be a
special cap on the manifold without valves leaving the
connection to the expansion tank open. Refer to the
manual on keel cooling and radiator cooling.

U.S.A.EDITION / WHISPER 6/8/12 / April 2004 13
2.5.14 Wiring codes and colours
AWG (American Wire Gauge)
Cable code number colour AWG cross section
battery > starter motor red 2 25 mm2
starter motor > DCC 1 red 10 6 mm2
starter motor > LCP 13 red 14 2,5 mm2
battery > ground black 2 25 mm2
ground> LCP ground(GND) 2 black 14 2,5 mm2
DDC > glow plugs 3 brown 12 4 mm2
DDC > starter solenoid 4 yellow 14 2,5 mm2
LCP > fuel lift pump + 5 brown 16 1,5 mm2
LCP > fuel lift pump - 15 black 16 1,5 mm2
DDC > LCD 5 grey 16 1,5 mm2
DDC > oil pressure switch 6 purple 17 1 mm2
LCP > oil pressure switch 6 purple/black 17 1 mm2
DDC > water temperature switch 7 blue 17 1 mm2
LCP >water temperature switch 7 blue/black 17 1 mm2
DDC > exhaust temperature switch 8 blue/green 17 1 mm2
LCP > exhaust temperature switch 8 blue/rose 17 1 mm2
DCC > fuel solenoid (hold) 9 green 16 1,5 mm2
DCC > fuel solenoid (pull) 20 pink 16 1,5 mm2
DCC > fuel solenoid (com.) 17 black 16 1,5 mm2
B+ terminal alternator > starter motor 21 red 10 6 mm2
DCC >R terminal alternator 18 wit 16 1,5 mm2
DCC > L terminal alternator 19 orange 16 1,5 mm2
DCC > current measuring transformer 11 black 17 1 mm2
DCC >current measuring transformer 11 red 17 1 mm2
DCC > current measuring transformer 22 black 17 1 mm2
DCC >current measuring transformer 22 red 17 1 mm2
DCC > LCP 12 black 16 1,5 mm2
DCC > LCP 14 red 16 1,5 mm2
DCC > LCP 16 red/green 16 1,5 mm2
DCC > generator AC output 33 brown 17 1 mm2
DCC > generator AC output 33 blue 17 1 mm2
DCC > generator AC output 44 brown 17 1 mm2
DCC > generator AC output 44 blue 17 1 mm2
DDC=Digital Diesel Control Unit
LCP=Local Control Panel
INFORMATION

14 April 2004 / WHISPER 6/8/12 / U.S.A.EDITION
INFORMATION
2.5.15 Lay out control PCB
J20
PUMP
J21
ALT
J1
ALT
J2
REGULATOR
J18 J19 J22
START/STOP
J8 J9
-
J10
-
J11
J12
- -
J13
- -
J14 J16
-
J15 J17
-
WCH/0
--
TAILOR MADE ENERGY
ALT-L
J3
J4 J6
+
J5 J7
+
MASTERVOLT
+
+
10A 3A
F3
10A
ALT
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
BATTERY
RED 25
12VDC
RED 2,5 (13)
RED 6 (1)
BLACK 25
GROUND TO
BLACK 2,5 (2) J17
WATER TEMP.
SWITCH
EXHAUST TEMP.
SWITCH
OIL PRESS.
SWITCH
GLOW (PREHEAT)
PLUGS
MOTOR
STARTER
CURRENT MEASURING
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 1,5 (17) J16
GREY 1,5 (5)
GREY 1,5 (5)
BLACK (11)
RED (11)
YELLOW 2,5 (4)
BROWN 4 (3)
RED/GREEN 1 (16)
R
B
L
P
RED (PULL)
BLUE (COM.)
WHITE (HOLD)
ALTERNATOR
FUEL
SOLENOID
RED 6 (21)
ORANGE 1,5 (19)
GREEN 1,5 (9)
PINK 1,5 (20)
RED 1,5 (14)
WHITE 1,5 (18)
BLACK 1,5 (22) J15
-+
PUMP
FUEL LIFT
ENGINE BLOCK
(OPTIONAL)
(OPTIONAL)
BATTERY
SWITCH
TO GENERATOR AC OUTPUT
AC-1
BROWN (33)
BLUE (33)
AC-1
BROWN (44)
BLUE (44)
RED (22)
BLACK (22)
CURRENT MEASURING
TRANSFORMER
CONTROL PANEL TO REMOTE
Fig. 6: Lay out control PCB

U.S.A.EDITION / WHISPER 6/8/12 / April 2004 15
2.5.16 Electrical diagram 120/240V 60 Hz.
STATOR
N
120-240V 60Hz
PE
L1
ROTOR
L2
EARTH AND NEUTRAL
CONNECTED
EARTH AND NEUTRAL NOT CONNECTED
EARTH AND NEUTRAL CONNECTED
DCC/AC-1
BROWN (33)
YELLOW/GREEN
BLUE (33)
120V 60Hz
BROWN
L1
BLUE
N
YELLOW/GREEN
BROWN
120V 60Hz
PE
L1
TRANSFORMER
BLACK
BLACK
(22)
DCC/ct-2
DCC/AC-2
TRANSFORMER
CURRENT
BROWN (44)
BROWN (33) BLUE (33)
DCC/AC-1
RED
(22)
RED
DCC/ct-1
(11) (11)
CURRENT
L2
BLUE (44)
YELLOW/GREEN
BLACK
YELLOW/GREEN
120-240V 60Hz
BLUE
PE
N
BROWN
L1
DCC/ct-1
(11)(11)
CURRENT
TRANSFORMER
BLACKRED
(22) (22)
DCC/ct-2
BLACKRED
CURRENT
TRANSFORMER
TRANSFORMER
CURRENT
DCC/AC-1
BROWN (33)
YELLOW/GREEN
BLUE (33)
DCC/ct-1
BLUE
N
YELLOW/GREEN
PE
RED
DCC/ct-2
(22)
BLACK
(22)
RED
(11)
BLACK
(11)
TRANSFORMER
CURRENT
MAIN WINDING
(4)
MAIN WINDING
(4)
(3)
(3)
EXCITATION
WINDING
(2)
(1)
YELLOW/GREEN
DCC/AC-1
BROWN (33) BLUE (33)
BLUE
YELLOW/GREEN
TRANSFORMER
RED
(11)
DCC/ct-1
BLACK
(11)
CURRENT
CAPACITOR
BROWN
DCC/ct-2
(22)
RED
(22)
BLACK
DCC/AC-2
BROWN (44) BLUE (44)
CURRENT
TRANSFORMER
BLACK
Fig. 7: Lay out control PCB.
INFORMATION

16 April 2004 / WHISPER 6/8/12 / U.S.A.EDITION
OPERATION
Fig. 9:
2.5.17 Diagram electronic governor (optional)

U.S.A.EDITION / WHISPER 6/8/12 / April 2004 17
INFORMATION
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 and connecting the digital remote
control panel.
3.2 OPERATION INSTRUCTIONS
3.2.1 Summarised operating instructions (daily use)
Routine "pre-start" checks:
1Check oil level (refer to fig. 10).
2Engine cooling system (all valves open).
3Power 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.
4Switch on battery switch (when installed).
5Fuel 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:
1Check for abnormal noise or vibration
2Check the voltage
3Check sea water flow at exhaust outlet
4Power source selector switch (off/shore power/gene-
rator power). Switch to power source generator. If a
MASTERSWITCH is installed, this is operating auto-
matically.
5Before loading the generating set up to maximum,
have it run warm. Continuous load should be restric-
ted to 70 % of maximum load.
Stopping generator:
1Switch 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.
2Press the STOP button.
3Close the inlet sea water cock.
4Switch to another AC 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:
1If there is any damage caused by transport or instal-
lation.
2Check if installation conforms with the installation
instructions.
3Ensure the generating set is free to turn without ob-
struction.
4Check all hoses and hose connections for leaks.
5Check all cables and cable end terminal connections.
6Check the engine and generator mounting bolts.
Routine "pre-start" checks:
1Check engine oil level.
The generator switches off in case 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.
2Check sea water cocks. Do not forget the valve of the
water outlet in case of a water/exhaust gas separator.
3Check the water strainer.
4Check for leakage’s.
5Regularly check the siphon vent in the cooling water
supply.
6If no MASTERSWITCH is used: Switch main Power
Source Selector switch to "OFF" or switch off all devices.
1
2
Fig. 10.
1Max. oil level;
2Min. oil level.

18 April 2004 / WHISPER 6/8/12 / U.S.A.EDITION
OPERATION
7Switch on the battery switch.
Starting the generator:
By pushing the start button briefly the electric system
is activated, the fuel lift pump starts pumping and the
starting procedure will begin. (By pushing the stop
button the system is deactivated)
The first time starting up or after running out of fuel it
could be necessary to prime the fuel system. (Refer
to bleeding fuel system instructions in the
maintenance chapter).
Arestart protection prevents for starting the engine while
already running which could cause damage.
In the event of starting problems (nume-
rous attempts are made), close the sea-
water inlet cock while cranking to prevent
the outlet system and engine to fill up with
water.
During the starting process, the cooling water pump is
driven with the engine. The cooling water is discharged
to the exhaust outlet, since the engine does not run, the
exhaust pressure is not high enough to expel this water.
Open the valve directly when the engine starts to prevent
for damaging the impeller.
Water in the cylinders will cause serious damage to the
engine. For instance; a bent piston rod or a cracked cylin-
der head. In fact water in the cylinders is the main cause
for engine damage in pleasure craft.
Checks once the generator is in operation:
1Check for abnormal noise or vibration.
2Check the voltage.
3Check coolant flow.
Always check immediately after starting the generator
if cooling water flows at the exhaust outlet. If this is
not the case, check the cooling water pump. After
having become acquainted with the generator you will
be able to recognise the coolant flowing through the
system by listening for the noise of the water which is
expelled.
Be aware that especially in harbours the
coolant water inlet can easily be blocked
by floating objects.
4Power source selector switch (off/shore power/gene-
rator power). Switch to power source generator. If a
MASTERSWITCH is installed, this is operating auto-
matically.
Before loading the generating set up to maximum,
have it run warm. The first 50 hours of running the
continuous load should be restricted to 70 % of maxi-
mum load. Running for long periods at no load or light
load in the first 50 hours can cause cylinder glazing
and high oil consumption.
Engine load during longer operation:
Please ensure that the generating set is not overloaded.
Overloading occurs when the electrical load (demand) is
so high that the generator cannot be turned around
properly by the diesel engine. Overloading causes the
engine to rum rough, while using oil and excessive fuel
and producing soot by the exhaust. The engine can even
stop.
The generator should therefore only be loaded at the
maximum rated power for short periods (2-3 hours) only!
The high peak current is meant for the ability to start
electrical devices, that need a high current for starting
especially electric motors and compressors (from a still
stand state).
In order to prolong the generating set’s life expectance,
the nominal electrical demand on the system should be
about 70% or the rated generating set’s maximum load.
Please note this when switching on your electrical
devices!
Nevertheless, the Whisper 6/8/12 is designed so as not
to overheat, even under extreme conditions.
Never remove the battery while the engine
is running, or any electrical cable while the
battery is connected in the circuit. Only
disconnect the battery with the engine
stopped and all switches in "OFF" position.
Stopping the generating set:
1Avoid stopping of the generator abruptly after a long
period of operation at high load! Doing so, you avoid
unnecessary thermal load to your generating set!
Act as follows:
Prior to switching off the generating set, decrease the
generator load (i.e. turn off most electrical users) and
let the generator run at low load for approx. 5 minutes
to allow the engine to get properly cool ( the influent
sea water must flow through the system in order to

U.S.A.EDITION / WHISPER 6/8/12 / April 2004 19
cool the engine).
If the generator is operating in a hot environment and
you do not act as given above, the excessive heat in
the engine can trip the "high temp" alarms. In that
case, a restart of the engine is not possible for some
time. It is also recommended to switch off electrical
users prior to stopping the generator. Because of the
voltage drop that occurs as the engine comes to a
halt. Such voltage drops may cause damage to elec-
tric motors, compressors (in refrigerators or air condi-
tioners etc.).
2Press the STOP button.
3Close the inlet sea water cock.
4Switch to an other AC power source, if available. If a
Masterswitch is installed, this is done automatically.
If the engine is not running and failure and
charging LED is blinking, reset by stop but-
ton, otherwise it will drain the start battery.
INFORMATION

20 April 2004 / WHISPER 6/8/12 / U.S.A.EDITION
4 MAINTENANCE
4.1 ALTERNATOR
The alternator does not require any maintenance. Perio-
dic inspection and cleaning is recommended, depending
on environmental conditions.
However when the alternator has been idle for a long
period attention to winding condition is recommended.
The condition of windings can be assessed by measure-
ment of insulation resistance to earth.
The CAPACITOR should be disconnected during this
test. A 500V ‘Megger’ or similar instrument should be
used. The insulation resistance to earth of all windings
should be in excess of 1.0 MOhm. Should the insulation
resistance be less than this value, drying out the genera-
tor windings is essential. Drying out can be carried out by
direct warm air from a fan heater or similar apparatus into
the generator air inlets or outlets.
All bearings are greased for life and not regreasable.
4.2 ENGINE
4.2.1 Preliminary instructions
All regular maintenance can be executed when the en-
closure is open. When oil and dirt has gathered in the
enclosure measures has to be taken to avoid spilling oil
and polluting the environment.
The first service on the engine should be carried out after
50 hours of its life and after a major overhaul. In the first
50 hours the engine should receive special attention:
Long periods of light or no load running in the first 50
hours may lead to cylinder glazing and high oil consump-
tion.
For the same reason it is of the greatest
importance to use the right oil specifica-
tion.
The first time starting up or after running out of fuel it
could be necessary to prime the fuel system.
4.2.2 Bleeding fuel lines
Ensure there is sufficient fuel. The system is self
bleeding. The first time starting up or after running out of
fuel it could be necessary to prime the fuel system. Push
“start” and monitor the display. Extend fuel pumping time
by pushing “stop” when the display indicates “preheat”
and push “start“ again.
4.2.3 Valve clearance
When the engine is in cold condition both valves should
have a clearance of 0,01 inch (0.25 mm). The adjustment
has to be done at TDC (refer to § 5.4.2).
4.2.4 Replacing fuel filter
Filter change depends on contamination of the fuel, but
should be done however, at least every 300 running
hours. Before changing the filter, clamp off the supply
line. Remove the hoses from filter and attach them on the
new filter again. The arrow on the filter housing indicates
the direction of the flow. A clogged filter results in a lack
of output of the generating set.
4.2.5 Replacing the oil filter
The oil filter is in front of the service side. Replacement
has to be executed according to the schedule in this
manual. Drain the oil using the sump pump and put some
tissues under the filter.
Asmeer of oil has to be put on the seal of the filter before
fitting the filter. The filter should be fastened manually:
when the rubber touches the metal turn 3/4 further.
MAINTENANVE
1
2
3
Fig. 11: Bleeding fuel lines. 1= fuel bleeding screw
Fig. 12.