Mastervolt WHISPER 9.5 ULTRA User manual

USERS MANUAL U.S.A EDITION
WHISPER 9.5/11 ULTRA
- 1800 RPM -
Marine diesel generating set 120/240V / 60Hz
Digital Diesel Control
MASTERVOLT
Snijdersbergweg 93,
1105 AN Amsterdam
The Netherlands
Tel.: [phone]
Fax.: [phone]
www.mastervolt.com V3. August 2009
Art.nr. 50200227

TABLE OF CONTENTS
2Copyright © 2009 Mastervolt / August 2009 / WHISPER 9.5 & 11 ULTRA / US
Copyright © 2009 Mastervolt. All rights reserved.
Reproduction, transfer, distribution or storage of part or all of the contents in this document in any form without the prior written
permission of Mastervolt is prohibited.
TABLE OF CONTENTS:
1INTRODUCTION.............................................................................................................................................................. 4
1.1 General .............................................................................................................................................................. 4
1.2 Service and maintenance................................................................................................................................... 4
1.3 Guarantee .......................................................................................................................................................... 4
1.4 Liability ............................................................................................................................................................... 5
1.5 Identification ....................................................................................................................................................... 6
1.5.1 General.............................................................................................................................................. 6
1.5.2 Identification plate ............................................................................................................................. 6
2INFORMATION................................................................................................................................................................ 7
2.1 Safety ................................................................................................................................................................. 7
2.1.1 General.............................................................................................................................................. 7
2.1.2 Electrical safety ................................................................................................................................. 7
2.1.3 Earth insulation failures ..................................................................................................................... 7
2.1.4 Installation ......................................................................................................................................... 7
2.1.5 Operation........................................................................................................................................... 8
2.1.6 Fire and explosion ............................................................................................................................. 8
2.1.7 Chemicals.......................................................................................................................................... 8
2.2 Transport, lifting and storage.............................................................................................................................. 9
2.3 The Whisper 9.5 / 11 ULTRA ............................................................................................................................. 9
2.3.1 Features ............................................................................................................................................ 9
2.3.2 Remote control .................................................................................................................................. 9
2.3.3 Documentation .................................................................................................................................. 9
2.3.4 Accessories included in the standard delivery...................................................................................9
2.4 Components ..................................................................................................................................................... 10
2.4.1 Main components to identify............................................................................................................ 10
2.4.2 Generator control panel................................................................................................................... 12
2.4.3 Remote control panel ...................................................................................................................... 12
2.5 Technical Information ....................................................................................................................................... 12
2.5.1 AC alternator ................................................................................................................................... 12
2.5.2 Engine ............................................................................................................................................. 12
2.5.3 Digital Diesel Control system........................................................................................................... 12
2.5.4 Battery charger................................................................................................................................ 12
2.5.5 Alarms and shut down ..................................................................................................................... 13
2.5.6 Control............................................................................................................................................. 13
2.5.7 Remote control ................................................................................................................................ 13
2.5.8 Hour counter.................................................................................................................................... 13
2.5.9 Load indicator.................................................................................................................................. 13
2.5.10 Fuel specification............................................................................................................................. 13
2.5.11 Oil information ................................................................................................................................. 13
2.5.12 Cooling liquid................................................................................................................................... 13
2.5.13 Technical data ................................................................................................................................. 14
2.5.14 Wiring codes and colours ................................................................................................................ 15
2.5.15 Lay out control wiring....................................................................................................................... 16
2.5.16 Electrical diagram 120V – 240 V AC / 60 Hz ................................................................................... 18
2.5.17 Diagram electronic governor Whisper 11 ULTRA............................................................................ 19

TABLE OF CONTENTS
US / WHISPER 9.5 & 11 ULTRA / August 2009 / Copyright © 2009 Mastervolt 3
3OPERATION.................................................................................................................................................................. 20
3.1 General ............................................................................................................................................................ 20
3.2 Operating Instructions ...................................................................................................................................... 20
3.2.1 Summarised operating instructions (daily use)................................................................................ 20
3.2.2 Extended operating instructions ...................................................................................................... 20
4MAINTENANCE............................................................................................................................................................. 23
4.1 Alternator.......................................................................................................................................................... 23
4.2 Engine .............................................................................................................................................................. 23
4.2.1 Preliminary instructions ................................................................................................................... 23
4.2.2 Bleeding fuel lines ........................................................................................................................... 23
4.2.3 Valve clearance............................................................................................................................... 23
4.2.4 Replacing fuel filter .......................................................................................................................... 23
4.2.5 Replacing oil filter ............................................................................................................................ 23
4.2.6 Readjustment V-beltplacing oil filter ................................................................................................ 24
4.3 Regular maintenance ....................................................................................................................................... 24
4.3.1 Maintenance schedule..................................................................................................................... 25
4.3.2 Putting out of service ....................................................................................................................... 26
5TROUBLE SHOOTING.................................................................................................................................................. 27
5.1 Alternator/ electrical faults ................................................................................................................................ 27
5.1.1 General............................................................................................................................................ 27
5.1.2 Trouble shooting table ..................................................................................................................... 27
5.2 Engine faults..................................................................................................................................................... 28
5.2.1 General............................................................................................................................................ 28
5.2.2 Trouble shooting table ..................................................................................................................... 29
5.2.3 Warnings ......................................................................................................................................... 31
5.2.4 Service address............................................................................................................................... 32
5.3 Special procedures alternator........................................................................................................................... 32
5.3.1 Residual voltage check / excitation procedure (Whisper 9.5 Ultra only) .......................................... 32
5.3.2 Testing rotary rectifier diodes .......................................................................................................... 32
5.3.3 Winding resistant values.................................................................................................................. 32
5.3.4 Meggering ....................................................................................................................................... 32
5.4 Special procedures engine ............................................................................................................................... 33
5.4.1 Setting the RPM .............................................................................................................................. 33
5.4.2 Adjusting valve clearance and retightening the cylinder head bolts. ............................................... 33
5.4.3 Measuring exhaust backpressure.................................................................................................... 34
5.4.4 Disassembling instructions .............................................................................................................. 35
6SPARE PARTS LIST..................................................................................................................................................... 36
MAINTENANCE LOG ............................................................................................................................................................... 38

INTRODUCTION
4Copyright © 2009 Mastervolt / August 2009 / WHISPER 9.5 & 11 ULTRA / US
1 INTRODUCTION
1.1 GENERAL
The Whisper 9.5/11 ULTRA Marine 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 statements contained
within this publication are given with our best intentions
and are believed to be correct at the time of going to
press.
All of the specifications, provisions and instructions
contained in this manual apply solely to standard versions
of the Mastervolt Whisper 9.5/11 ULTRA generating set.
This manual is valid for the following models:
Part
number Description
51106055 Whisper 9.5 Ultra 120/240V 1800RPM
51106056 Whisper 9.5 Ultra 120/240V 1800RPM -
ungrounded
51189055 Whisper 11 Ultra 120/240V 1800RPM
51189056 Whisper 11 Ultra 120/240V 1800RPM -
ungrounded
For other models see other manuals available on our
website: www.mastervolt.com
Our policy is one of continued development and we re-
serve the right to amend any technical information without
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
consequences thereof.
Keep this manual at a secure place!
WARNING
A warning symbol draws attention to special
warnings, instructions or procedures which, if
not strictly observed, may result in damage or
destruction of equipment, severe personal
injury or loss of life.
DANGER
This danger symbol refers to electric danger
and draws attention to special warnings,
instructions or procedures which, if not strictly
observed, may result in electrical shock which
will result in severe personal injury or loss of
life.
1.2 SERVICE AND MAINTENANCE
Regular service and maintenance should be carried out
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
generating 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 our guarantee scheme are given
here in more detail:
Guarantee 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. If in doubt ask!

INTRODUCTION
US / WHISPER 9.5 & 11 ULTRA / August 2009 / Copyright © 2009 Mastervolt 5
DAMAGE CAUSED BY THE INGRESS OF
WATER IS NEVER COVERED BY
GUARANTEE
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 guarantee.
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
guarantee claims will not be honoured.
Example 4: 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.
Guarantee 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 authorized
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. For details refer to
Mastervolt U.S.A.
Goods to be delivered under guarantee 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
guarantee a credit will not be issued. For example if a
Printed Circuit Board is returned with clear damage
caused by seawater, guarantee will be refused.
Freight costs to deliver spares by normal mail or carriers is
covered under guarantee. 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
guarantee.
Additional agreements could be part of the contract of
delivery.
If any problem arises which could be subject of guarantee,
procedures should be followed as described in the
guarantee conditions, unauthorised repairs could lead to
further damage and violate the guarantee conditions.
Should work take place, which is not in
accordance 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 specifications.
In all these cases the guarantee may become
invalid. Use original spareparts 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
liability 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.

INTRODUCTION
6Copyright © 2009 Mastervolt / August 2009 / WHISPER 9.5 & 11 ULTRA / US
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 correct
specifications.
1.5.2 Identification plate
All required identification data are on the identification
plate. For location of the identification plate see figure 1
Fig. 1: Location identification plate.
1 The identity of the generating set is given by the
SERIAL NUMBER.
Example:
When this number is available the manufacturer can
trace the specifications of the generating set. On the
identification plate are also some basic features of the
set:
2 POWER
The identification plate gives the nominal maximum
continues load in kVA (= kW) calculated with 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 as shown on the identification plate.
Power is rated at an ambient temperature of 104°F
(40°C) and a seawater temperature of 77°F (25ºC).
For higher temperatures the generating 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). 60 Hz correlates with
1800 RPM.
5 CURRENT shows the maximum current that is
acceptable at the specified frequency, voltage and
power factor.
6 WEIGHT shows the net dry weight (approximately) in
kg. This is without fuel, oil, packing and external
installation equipment
7 CE-marking: 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,
safety of machinery, electric safety and electric
magnetic compatibility (EMC) and other relevant
directives.
Safety also relies on the installation, application and
circumstances. See also the remarks in this manual under
SAFETY
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 may have changed the
settings. Check the settings (voltage, frequency, rpm)
when there is any doubt.
SERIAL NO: : WO22A001
version “A”

INFORMATION
US / WHISPER 9.5 & 11 ULTRA / August 2009 / Copyright © 2009 Mastervolt 7
2 INFORMATION
2.1 SAFETY
2.1.1 General
When correctly installed and used in normal
circumstances 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 necessary
to take additional measures. Be aware of wet
conditions and hazardous environments
caused by explosive gases etc
2.1.2 Electrical safety
The voltage of 120/240 Volt generated by this
generating set is dangerous and if instructions
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
changes in your electrical system to be carried
out by qualified electricians.
•Connection and protection must be done in
accordance with local standards.
•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.
Warning signs indicate parts which could be
live.
2.1.3 Earth insulation failures
According to local regulations and depending on the
application it could be necessary to take measures for
protection against earth insulation failures.
With the USA versions “neutral” and “ground” are
connected with each other 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 be 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 L1. Of course this is the case
when using a Mastervolt Mass Systemswitch.
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 contain 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.

INFORMATION
8Copyright © 2009 Mastervolt / August 2009 / WHISPER 9.5 & 11 ULTRA / US
2.1.5 Operation
External moving parts like fans and V-belts are covered by
the soundshield and therefore the Whisper 9.5 / 11 ULTRA
is very safe when the soundshield is closed.
Nevertheless take note of the signs on the
generating set which show symbols in a
triangle indicating danger.
When service has to be carried out while the
engine is running, be aware of moving parts
like V-belts.
•The generating set should be operated by
authorised personnel only.
•Be aware of hot parts and especially parts of the
exhaust system and the cooling 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
corrected.
•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 a record of setting changes
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. Ensure for proper ventilation. Do not
smoke or allow sparks, flames, or other sources
of ignition around batteries.
•Keep a fire extinguisher on hand.
INCASEOFFIRE, DONOTOPENSOUNDSHIELD.
TOAVOID SERIOUS INJURY OR DEATH FROM FIRE
IMMEDIATELY DISCHARGE ENTIRE CONTENTS OF GASEOUS
SHUT DOWN ENGINES, GENERATOR SETS AND BLOWERS.
PORTABLE FIRE EXTINGUISHER THROUGH THIS PORT.
THROUGH
HERE
FIRE EXTINGUISHER PORT :
BREAK
Fig. 2: Fire extinguisher port.
•In case of fire do not open the soundshield. To
avoid serious injury or death from fire, shut down
engines, generator sets and blowers. Break
through the label which is indicated by BREAK
THROUGH HERE and then immediately
discharge entire contents of gaseous portable fire
extinguisher through the fire extinguisher port. On
the generating set this fire extinguisher port is
indicated by the label as shown in figure 2.
•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
contaminated 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.
•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

INFORMATION
US / WHISPER 9.5 & 11 ULTRA / August 2009 / Copyright © 2009 Mastervolt 9
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
of personal injuries, do not stand under the
generating set.
•Use soft slings to avoid damage
•On the engine are two hoist eyes which can be
used to take the generator out of the capsule.
They can also be used to lift the complete
generating set including the capsule.
•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
minimise 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 recharged
every 12 weeks.
2.3 THE WHISPER 9.5 / 11 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 guided
through the capsule’s sides. The set is not self contained
and is only operable after proper installation using
additional accessories and installation materials.
Installation accessories are listed in the installation manual
and are available through the supplier of the generating
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 Whisper generating set.
2.3.3 Documentation
Included in the delivery is:
•This users manual (number: 50200227)
•An installation manual (number: 50200237)
•A users manual for DCC (number: 50200261).
•A quick reference guide for DDC (number
50200275)
Not included in the standard delivery but available as
options are:
•Parts manual; number: 50200185
•Workshop manual; number: 50200172
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
•Expansion tank, hose and fittings
•Special hose connector for measuring exhaust
back pressure (refer to paragraph 5.4.3)

INFORMATION
10 Copyright © 2009 Mastervolt / August 2009 / WHISPER 9.5 & 11 ULTRA / US
2.4 COMPONENTS
2.4.1 Main components to identify
Fig. 3 Front View main components Whisper 9.5 Ultra and 11 Ultra
Fig. 4: Rear view main components Whisper 9.5 Ultra and 11 Ultra.
01 Temperature switch
exhaust
02 Cooling water injection
bend
03 Exhaust manifold (water-
cooled)
04 Starter motor solenoid
05 Heat exchanger
05a Starter motor
06 Alternator (12VDC)
07 Rubber engine mounting
08 Bypass cooling water in
09 Expansion tank
10 Bypass cooling water out
11 Exhaust hose Ø51mm
12 Remote control
13 AC power output
14 Power take off (PTO)
15 Injection pump air
bleeding screw
16 Hoist eye front
17 Fuel injection pump
18 Engine speed adjusting
screw
19 Fuel solenoid (Whisper
9.5 Ultra)
20 Electronic governor
(Whisper 11 Ultra)
21 Fuel filter
22 Engine oil filter
23 Fuel lift pump
24 Oil sump hand pump

INFORMATION
US / WHISPER 9.5 & 11 ULTRA / August 2009 / Copyright © 2009 Mastervolt 11
Fig. 5: Rear view main components Whisper 9.5 Ultra and 11 Ultra
Fig. 6: Top View main components Whisper 9.5 Ultra and 11 Ultra
25 Digital Diesel Control
(DDC)
26 Control panel
26a Identification plate
27 Fuses
27a Air cleaner element
28 Fuel injector (3x)
29 Glow plug (3x)
30 V-belt
31 Engine coolant pump
32 Raw water pump
33 Engine serial number
34 Filler cap engine oil
35 Battery -
36 Battery +
37 Raw water inlet
38 Fuel in
39 Fuel out
40 Coolant drain plug
41 Engine oil pressure switch
42 Engine oil dipstick
43 Hoist eye rear
44 Filler cap engine coolant
45 Rocker cover
46 Filler cap engine oil
47 Temperature switch
48 Thermostat housing
49 Failsafe
50 Rubber engine mounting

INFORMATION
12 Copyright © 2009 Mastervolt / August 2009 / WHISPER 9.5 & 11 ULTRA / US
2.4.2 Generator control panel
Start / Stop
Remove fuse
Internal fuel pump
Fuse 3A
before maintenance
Digital Diesel Control
Fuse 3A
Auxiliary
Fuse 10A External Fuel Pump Fuse 3A
Observe instructions in the manual
Replace fuseswith same type and rating
Whisper Digital Diesel OperationUnit
Fig: 9 Control panel.
Fig. 10 Digital Diesel Control unit
Fig. 11: Digital Diesel remote control panel
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 alternator is directly coupled, one
bearing, brushless, rotating field design, four poles (1800
RPM) and self regulating.
Residual magnetism causes a small voltage over the
stator windings and allows a current to flow in the
windings, which is magnified because of the feed back
effect between rotor and stator. The field windings in the
rotor are short-circuited over a diode to rectify the current.
A capacitor over an additional winding in the stator which
is at 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 9.5 / 11 ULTRA generating set is based on
the Mitsubishi S3L2 3 cylinder diesel engine. 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
supplied for industrial applications!
The engine fulfills EPA emission standards and is certified
and labelled as such..
2.5.3 Digital Diesel Control system
The standard electrical engine control system is 12 Volt
negative earth, non earth return (ungrounded) 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 in the black box 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 ±14.4V.
1 26 5
347

INFORMATION
US / WHISPER 9.5 & 11 ULTRA / August 2009 / Copyright © 2009 Mastervolt 13
2.5.5 Alarms and shut down
In the event of malfunctioning this will be indicated by the
failure light, details will be shown on the display and 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 occur.
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.
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
communication 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 that
helps to schedule maintenance.
2.5.9 Load indicator
On the remote control the load will be indicated on the
display and by the LED-bar. 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 to the standards for use in modern diesel
engines. Fuel free from water and contaminants is of the
utmost 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, CD, CF or CF_4.
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 15W40.
3 Oil capacity:
Excluding the oil filter the content of the crankcase is
3.9 U.S.qts (3.7 l). Including the oil filter it is 4.4
U.S.qts (4.2 l). Note that the engine may contain
some residual oil due to testing at the factory.
While filling, check the lubricating oil level by means
of the engine oil dipstick. Do not overfill with
lubricating oil as this may have a detrimental effect on
engine performance
4 Oil pressure
•Minimum at idle 98kPa (1 kgf/cm² - 14psi) (1 bar).
•Normal at 1800 RPM ±350kPa (3.5 kgf/cm² - 50
psi) (3.5 bar).
2.5.12 Cooling liquid
The engine is cooled by cooling liquid. The capacity of this
system of the Whisper 9.5 / 11 ULTRA is 3,7 US qts. (3.5
litres).
Always use coolant which is compatible with
aluminum components of the cooling system.
Do not mix coolants with different kinds of
chemical compound, as this may cause
congelation of the coolant. In case of doubt
refresh the content of the entire 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 13 °F (minus
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.

INFORMATION
14 Copyright © 2009 Mastervolt / August 2009 / WHISPER 9.5 & 11 ULTRA / US
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 calculated 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.
2.5.13 Technical data
GENERAL
Model WHISPER 9.5ULTRA WHISPER 11 ULTRA
RPM 1800 1800
Alternator water cooled, synchronous water cooled, synchronous
Engine Mitsubishi diesel, model S3L2 (Japan) Mitsubishi diesel, model S3L2 (Japan)
Number of cylinders 3 3
Displacement 80.4 cubic inches (1318 cm3) 80.4 cubic inches (1318 cm3)
Bore X stroke 3.07 x 3.62 inches (78x92 mm) 3.07 x 3.62 inches (78x92 mm)
Combustion air consumption 46 cf/m (1.3 m³/min.) 46 cf/m (1.3 m³/min.)
Continuous power engine 9.5 kW 11 kW
Cooling system indirect cooling by raw water, 4.8 – 6 US gpmin (18-22 l/min.)
Cooling water pump PTO driven Mastervolt self priming impeller pump, type M12
Fuel lift pump engine electric pump (12 V DC), additional pump available upon request
Starting battery (optional) 70 Ah 12V 70 Ah 12V
Fuel consumption 0.53 – 1.2 US gph 2-4.5 litre/hour, load dependent
Control Digital Diesel Control including automatic start/stop
ELECTRICAL SPECIFICATIONS
Model WHISPER 9.5ULTRA WHISPER 11 ULTRA
Output voltage 120V/240V 60 Hz alternating current (AC) single phase – dual voltage
Output rating at power factor cos phi = 1 9.5 kVA = 9.5kW 11 kVA = 11kW
Voltage tolerance ± 5% ± 5%
Frequency tolerance ± 5% ± 1%
Alternator Brushless, four pole, synchronous Brushless, four pole, synchronous
Voltage regulation: Capacitor Capacitor
MECHANICAL SPECIFICATIONS
Supply includes Sound shield with steel base, mounted on rubber anti vibration mounts. (Generator
set without sound shield is optional)
Dimensions hxwxd 25.0 x 35.4 x 22.6 inch (640 x 900 x 575 mm)
Colour Metallic silver / grey
Weight 340 kg including sound shield
Max. installation angle 25 degrees
Standard supplies Digital remote panel (approx.45 feet / 15m cable), fuel filter, fuel lift pump, user and
installation manuals
Optional: Installation kits, mobile (vehicle) version, non earth return (ungrounded), spare part
kits, PTO to drive a hydraulic pump

INFORMATION
US / WHISPER 9.5 & 11 ULTRA / August 2009 / Copyright © 2009 Mastervolt 15
2.5.14 Wiring codes and colours
number colour AWG cross section
battery > starter motor red 2 25 mm2
starter motor > DDC 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 12 4 mm2
DDC > glow plug 3 brown 12 4 mm2
DDC > starter solenoid 4 yellow 14 2,5 mm2
LCP > fuel lift pump + 5 grey 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
DDC > fuel solenoid (hold) 9 green 16 1,5 mm2
DDC > fuel solenoid (pull) 20 pink 16 1,5 mm2
DDC > fuel solenoid (com.) 17 black 16 1,5 mm2
B+ terminal alternator > starter motor 21 red 10 6 mm2
DDC >R terminal alternator 18 white 16 1,5 mm2
DDC > L terminal alternator 19 orange 16 1,5 mm2
DDC > current measuring transformer 11 black 17 1 mm2
DDC > current measuring transformer 11 red 17 1 mm2
DDC > current measuring transformer 22 black 17 1 mm2
DDC > current measuring transformer 22 red 17 1 mm2
DDC > LCP 12 black 16 1,5 mm2
DDC > LCP 14 red 16 1,5 mm2
DDC > LCP 16 red/green 16 1,5 mm2
DDC > generator AC output 33 brown 17 1 mm2
DDC > generator AC output 33 blue 17 1 mm2
DDC > generator AC output 44 brown 17 1 mm2
DDC > generator AC output 44 blue 17 1 mm2
DDC=Digital Diesel Control Unit
LCP=Local Control Panel

INFORMATION
16 Copyright © 2009 Mastervolt / August 2009 / WHISPER 9.5 & 11 ULTRA / US
2.5.15 Lay out control wiring
Fig 12a: Electrical Diagram control wiring Whisper 9.5 Ultra

INFORMATION
US / WHISPER 9.5 & 11 ULTRA / August 2009 / Copyright © 2009 Mastervolt 17
Fig 12b: Electrical Diagram control wiring Whisper 11 Ultra
See also chapter 2.5.17

INFORMATION
18 Copyright © 2009 Mastervolt / August 2009 / WHISPER 9.5 & 11 ULTRA / US
2.5.16 Electrical diagram 120V – 240 V AC / 60 Hz
Fig. 13: Electrical diagrams AC

INFORMATION
US / WHISPER 9.5 & 11 ULTRA / August 2009 / Copyright © 2009 Mastervolt 19
2.5.17 Diagram electronic governor Whisper 11
ULTRA
The Whisper 11 Ultra is equipped with an electronic
governor in addition to the mechanical governor that is on
other Whisper models. A governor keeps the speed
(RPM=Rotations Per Minute) of the engine at a fixed
value. The RPM of the engine correlates with the
frequency of the electrical output (1800 RPM =60 Hz) of
the alternator.
Under full load the RPM of the Whisper models that has
only a mechanical governor can drop 75 RPM (=2.5 Hz) at
full load and will go further down or collapse when further
loaded. However the engines with the electronic governor
will keep the RPM and frequency at the set value. As the
voltage is related to the frequency, the voltage will be
more stable as well.
The RPM represents power and the alternator performs
better as well on a higher speed. Whisper models with an
electronic governor will bring more power.
So the electronic governor offers three advantages: a
more stable frequency and voltage and more power.
The electronic governor system contains two parts:
1 The actuator controls the engine speed. This actuator
replaces the standard hold solenoid that is on all other
mechanical controlled Whisper engines. The actuator
controls the RPM directly on the fuel rack inside the
fuel pump without levers and other mechanical
transmissions.
2 A microprocessor keeps the speed at the set value by
controlling the actuator. The microprocessor is
programmed at the Mastervolt factory and many
parameters are set to perform well. It should not be
necessary to make adjustments. When adjustments
are necessary this can only be done with the help of
an interface to a computer and special software to get
access to the microprocessor.
The Mastervolt electronic governor does not need a pickup
device in the flywheel housing that counts the passing
tooth of the flywheel and determines the exact RPM of the
engine, because the processor uses the 60 Hz of the AC
output voltage as a reference.
Note: If you there is a pick up on your generator than you
have another model than referred to in this chapter; see
figure 12b
Fig 14: Diagram electronic governer

OPERATION
20 Copyright © 2009 Mastervolt / August 2009 / WHISPER 9.5 & 11 ULTRA / US
3 OPERATION
3.1 GENERAL
The generating set is operational after full installation and
filling up with: fuel, engine lubricating oil and cooling liquid,
connecting the battery to earth and connecting the digital
remote control panel.
Fig. 15:
3.2 OPERATING INSTRUCTIONS
3.2.1 Summarised operating instructions (daily
use)
Routine "pre-start" checks:
1 Check oil level (refer to fig. 15).
2 Water inlet (all valves open).
3 Power source selector switch (off/shore
power/generator power). Switch to power source
switch "OFF", or switch off all consumers in the usual
way. If a Mass Systemswitch is installed, this operates
automatically.
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 Check sea water flow at exhaust outlet
4 Power source selector switch (off/shore
power/generator power). Switch to power source
generator. If a Mass Systemswitch is installed, this
operates automatically.
5 Before loading the generating set up to maximum,
have it run warm. Continuous load should be
restricted 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 Close the inlet sea water cock.
4 Switch to an other AC power source, if available. If a
Mass Systemswitch 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
installation.
2 Check if the installation conforms to the installation
instructions.
3 Ensure the generating set is free to turn without
obstruction.
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 in the,
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.
1
2
1 Maximum oil level
2 Minimum oil level