Mastervolt Whisper 3.5 3000 RPM User manual

USERS MANUAL
WHISPER 3,5
- 3000 RPM -
Marine diesel generating set 230V / 50Hz
Digital Diesel Control
MASTERVOLT
Snijdersbergweg 93,
1105 AN Amsterdam
The Netherlands
Tel.: [phone]
Fax.: [phone]
www.mastervolt.com V5. May 2006
Art.nr. 50200302

CONTENTS
2May 2006 / WHISPER 3,5 / EN
This manual applies to the Mastervolt Whisper 3,5 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
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 Nameplate.........................................................................................................................................5
2INFORMATION................................................................................................................................................................ 6
2.1 Safety.................................................................................................................................................................6
2.1.1 General..............................................................................................................................................6
2.1.2 Electrical safety .................................................................................................................................6
2.1.3 Earth insulation failures.....................................................................................................................6
2.1.4 Installation.........................................................................................................................................7
2.1.5 Operation...........................................................................................................................................7
2.1.6 Fire and explosion.............................................................................................................................7
2.1.7 Chemicals..........................................................................................................................................7
2.2 TRANSPORT, LIFTING AND STORAGE...........................................................................................................8
2.3 THE WHISPER 3,5 ............................................................................................................................................8
2.3.1 Features............................................................................................................................................8
2.3.2 Remote control..................................................................................................................................8
2.3.3 Documentation ..................................................................................................................................8
2.3.4 Accessories included in the standard delivery...................................................................................8
2.4 Components.......................................................................................................................................................9
2.4.1 Main components to identify..............................................................................................................9
2.4.2 Generator control panel................................................................................................................... 10
2.4.3 Remote control panel ...................................................................................................................... 10
2.5 Technical Information....................................................................................................................................... 10
2.5.1 AC 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 information ................................................................................................................................. 11
2.5.12 Technical data................................................................................................................................. 12
2.5.13 Wiring codes and colours................................................................................................................ 13
2.5.14 Lay out control PCB......................................................................................................................... 14
2.5.15 Electrical diagram 230 V AC / 50 Hz ............................................................................................... 15

CONTENTS
EN / WHISPER 3,5 / May 2006 3
3OPERATION.................................................................................................................................................................. 16
3.1 General ............................................................................................................................................................ 16
3.2 Operating Instructions ...................................................................................................................................... 16
3.2.1 Summarised operating instructions (daily use)................................................................................ 16
3.2.2 Extended operating instructions ...................................................................................................... 16
4MAINTENANCE............................................................................................................................................................. 19
4.1 Alternator.......................................................................................................................................................... 19
4.2 Engine.............................................................................................................................................................. 19
4.2.1 Preliminary instructions ................................................................................................................... 19
4.2.2 Bleeding fuel lines ........................................................................................................................... 19
4.2.3 Valve clearance............................................................................................................................... 19
4.2.4 Replacing fuel filter.......................................................................................................................... 20
4.2.5 Cleaning oil strainer......................................................................................................................... 20
4.3 Regular maintenance ....................................................................................................................................... 20
4.3.1 Maintenance schedule..................................................................................................................... 21
4.3.2 Putting out of service....................................................................................................................... 21
5TROUBLE SHOOTING.................................................................................................................................................. 22
5.1 Alternator/ electrical faults................................................................................................................................ 22
5.1.1 General............................................................................................................................................ 22
5.1.2 Trouble shooting table..................................................................................................................... 22
5.2 Engine faults..................................................................................................................................................... 23
5.2.1 General............................................................................................................................................ 23
5.2.2 Trouble shooting table..................................................................................................................... 23
5.2.3 Warnings......................................................................................................................................... 26
5.2.4 Service address............................................................................................................................... 26
5.3 Special procedures alternator........................................................................................................................... 26
5.3.1 Residual voltage check / excitation procedure ................................................................................ 26
5.3.2 Testing rotary rectifier diodes .......................................................................................................... 26
5.3.3 Winding resistant values.................................................................................................................. 27
5.3.4 Meggering ....................................................................................................................................... 27
5.4 Special procedures engine............................................................................................................................... 27
5.4.1 Setting the RPM .............................................................................................................................. 27
5.4.2 Tightening torques........................................................................................................................... 27
5.4.3 Measuring exhaust backpressure.................................................................................................... 27
5.4.4 Disassembling instructions.............................................................................................................. 28
6SPARE PARTS LIST..................................................................................................................................................... 29
MAINTENANCE LOG ............................................................................................................................................................... 31

INTRODUCTION
4May 2006 / WHISPER 3,5 / EN
1 INTRODUCTION
1.1 GENERAL
The Whisper 3,5 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.
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
consequences thereof.
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 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. Some aspects of our warranty scheme are given
here in more detail: The guarantee period is two years,
limited to 1000 running hours. 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. If in doubt ask!
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.
Mastervolt cannot be held responsible for damage caused
by the unattended running generator.

INTRODUCTION
EN / WHISPER 3,5 / May 2006 5
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 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.
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.
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 certificate, 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
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.
1.5 IDENTIFICATION
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.
1.5.1 Nameplate
All required identification data are on the nameplate.
1 The identity of the generating set is given by the
SERIAL NUMBER.
When this number is available the manufacturer can
trace the specifications of the generating set. On the
nameplate are also some basic features of the set:
2 POWER
The nameplate gives the nominal maximum 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
Model Whisper 3,5
Article number 050900500
Serial number
Max. power 3,6 KVA cos phi =0,8
3 KVA cos phi = 1
Voltage 230V ± 5%
Frequency 50 Hz
Current 13A
Phase Single phase
Dimensions
L x W x H 505x400x500mm
Weight 97 kg
Fig 1: Nameplate

INFORMATION
6May 2006 / WHISPER 3,5 / EN
power should never exceed 3 kW. Power is rated at
an ambient temperature of 40°C and a seawater
temperature of 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). 50 Hz correlates with
3000 rpm, 60 Hz correlates with 3600 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 The CE symbol shows that the generating set is build
according to European Community safety regulations.
This includes the regulations regarding the safety of
pleasure craft, machinery, 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.
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 230 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.
In the standard delivery “neutral” and “ground” are not
connected. To make a connection between “neutral” and
“ground” could be necessary as part of a specific
insulation failure protection system.

INFORMATION
EN / WHISPER 3,5 / May 2006 7
Small pleasure craft in Europe is submitted to The
Recreational Craft Directive 94/25/EC. The guidelines of
this directive refer to (ISO 13297).
When the installation complies with this standard the
“neutral” and “ground” should be connected on the
generating set. (Refer to the electrical diagram, page 15)
In all situations the transfer switches between
shore, inverter and generator should switch
both neutral and L1. Of course this is the case
when using a Mastervolt Masterswitch.
Be aware that insulation protection systems can be
different for different applications and even within the ship
there could be different standards for different spaces. We
did refer to the Recreational Craft Directive that applies to
pleasure craft up to 24 m of length. Sometimes one has to
comply with other standards such as the rules of
certification societies like Lloyds Register of Shipping or
Veritas, regulations for the protection of personal, building
legislation, etc. It is of the greatest importance to have
expert advice on this issue.
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.
2.1.5 Operation
The Whisper 3,5 generating set does not have any
external moving parts like fans and V-belts and therefore
is very safe.
Nevertheless take note of the signs on the
generating set which show symbols in a
triangle indicating danger.
•The generating set should be operated by
authorised personnel only.
•Be aware of hot parts and especially parts of the
exhaust system.
•If the generating set is unsafe, fit danger notices
and disconnect the battery negative (-) 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
negative (-) 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.
•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.

INFORMATION
8May 2006 / WHISPER 3,5 / EN
•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 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
of personal injuries, do not stand un-der the
generating set..
•Use soft slings to avoid damage
•Included in the delivery is a lifting eye, 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
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 3,5
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 left side. 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 genera-ting
set. The full automatic Digital Control is based on
microprocessor technology. Several automatic start/stop
functions can be programmed and monitored (refer to
Digital Diesel Control users manual).
2.3.2 Remote control
The full automatic remote control panel including 15 mtr
cable comes as standard with the Wisper 3,5.
2.3.3 Documentation
Included in the delivery is this users manual (number:
50200302) an installation manual (number: 50200311) and
a users manual for DCC (number: 50200261).
Not included in the standard delivery but available as
options are:
•Parts manual; number: 50200180
•Workshop manual; number: 50200170
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
•Fuel filter
•Fuel lift pump
•Lifting eye
•Special hose connector for measuring exhaust
backpressure (Refer to paragraph 5.4.3).

INFORMATION
EN / WHISPER 3,5 / May 2006 9
2.4 COMPONENTS
2.4.1 Main components to identify
1 Air inlet;
2 Starter motor;
3 Battery connection (positive);
4 Battery connection (negative);
5 AC 230 V wiring;
6 AC 230 V output connection box;
7 Fuel filter;
8 Fuel pipe inlet;
9 Fuel pipe return;
10 Bypass hose air vent;
11 Cooling water in;
12 Exhaust manifold (water cooled);
13 Thermo-switch exhaust;
14 Glow plug;
15 Injector;
16 Valve cover;
17 Decompression handle;
18 Oil filler cap;
19 Solenoid fuel valve;
20 Electric fuel lift pump;
21 Cooling water pump;
22 Oil pressure pump;
23 Fuel pressure pump
24 Oil pressure switch;
25 Oil sump pump;
26 Exhaust connection;
27 Fuel return;
28 Oil filler cap/ oil level indicator;
29 Control panel;
30 Capacitor;
31 Fuse 1;
32 Fuse 2;
33 Remote control cable;
34 Stop solenoid;
35 Oil strainer cover;
36 Start button;
37 Digital Diesel Control unit;
38 RPM set screw;
39 Oil temp switch;
40 Plug screw;
41 Heat exchanger.
Fig. 2: Overview Whisper 3,5.
18
19
27
25
40
23
38
37
30
29
31
32
36
34
24
28
1
39
14
2
41
20
7
26
3
9
4
10
11
6
1
17
15
16
12
13
3
4
21
22
35
33
20
5
8

INFORMATION
10 May 2006 / WHISPER 3,5 / EN
2.4.2 Generator control panel
Fig. 3: Control panel.
1 Fuse 3A;
2 Fuse 3A;
3 Start/stop button.
Fig... 4: Digital Diesel Control unit
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, two poles (3000
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 3,5 generating set is based on the Kubota
OC60 1 cylinder diesel engine. The engine is indirectly
injected. The engine is oil cooled and the oil 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!
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 on top of the alternator.
1
2
3
3A 3A
Fig. 5: Digital Diesel remote control panel.
1 26 5
347

INFORMATION
EN / WHISPER 3,5 / May 2006 11
2.5.4 Battery charger
There is an extra winding in the alternator generating 6
Amp 12 V. This current is rectified on the control PCB to
charge the battery. Both the current and the voltage are
regulated.
2.5.5 Alarms and shut down
In the event of malfunctioning this will be indicated by the
failure light and details 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 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. Stopping the engine is executed by the ‘pull’
solenoid, at the same time the fuel valve solenoid 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 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 Kubota engine must be
run on heavy duty lubricating oil meeting the
requirements of API class CC or CD.
It is very important to use the correct oil
specification. Very often local oil suppliers
recommend a higher class, because they
assume that a higher class is allowed. This is
not the case. One should not follow these
recommendations.
Using the wrong specification will cause high
oil consumption.
2 Oil viscosity:
We recommend a multigrade oil 15W40.
3 Oil capacity:
Excluding the oil cooler the content of the crankcase
is 1,3 l. including the oil cooler it is 1,5 l.
Do not overfill with lubricating oil as this may have a
detrimental effect on engine performance.
4 Oil pressure
•Minimum at idle 49 Kpa (0,5 kgf/cm2 - 7psi).
•Normal at 3000 rpm between 147 and 490 Kpa
(1,5 up to 5 kgf/cm2 - 21 up to 71 psi).
•Minimum at 3000 rpm 98 Kpa (1,0 kgf/cm 2 - 14
psi).

INFORMATION
12 May 2006 / WHISPER 3,5 / EN
2.5.12 Technical data
GENERAL
Model WHISPER 3,5
RPM 3000
Alternator water cooled, synchronous
Engine Kubota diesel, model OC60 (Japan)
Number of cylinders 1
Displacement 276 cm3
Bore X stroke 72x68 mm
Combustion air consumption 0,38 m3/min.. at nominal RPM
Continuous power engine 3 kW nett.
Cooling system Indirect cooling by raw water.
Cooling water pump pto driven Mastervolt self priming impeller pump, type K
Fuel lift pump engine electric pump (12 V DC), additional pump available upon request
Starting battery (optional) 55-90 Ah
Fuel consumption 0.7-1.4 litre/hour, load dependent
Control Digital Diesel Control including automatic start/stop
ELECTRICAL SPECIFICATIONS
Output voltage 230V 50 Hz alternating current (AC) single phase
Output rating 3,6 KVA cos phi = 0,8; 3 KVA = 3 kW cos phi = 1
Voltage tolerance ± 5%
Frequency tolerance ± 5%
Alternator brushless, two pole, synchronous
MECHANICAL SPECIFICATIONS
Supply includes generating set, built into tugged GRP sound shield with steel base frame, mounted
on rubber anti vibration mounts
Dimensions hxwxd 500x505x405 mm
Colour top white, bottom green
Weight 97 kg including sound shield
Max. installation angle 25 degrees
Standard supplies Digital Diesel Control, remote panel (15 m cable)
Optional mobile (vehicle) version, non earth return, spare part kits

INFORMATION
EN / WHISPER 3,5 / May 2006 13
2.5.13 Wiring codes and colours
number colour cable code no
cross section
battery > starter motor red 16 mm2
starter motor > DCC 1 red 6 mm2
starter motor > LCP 13 red 2,5 mm2
battery > ground black 16 mm2
ground > LCP ground (GND) 2 black 2,5 mm2
DDC > glow plug 3 brown 4 mm2
DDC > starter solenoid 4 yellow 2,5 mm2
LCP > fuel lift pump + 5 brown 1,5 mm2
LCP > fuel lift pump – 15 black 1,5 mm2
DDC > LCD 5 grey 1,5 mm2
DDC > oil pressure switch 6 purple 1 mm2
LCP > oil pressure switch 6 purple/black 1 mm2
DDC > oil temperature switch 7 blue 1 mm2
LCP > oil temperature switch 7 blue/black 1 mm2
DDC > exhaust temperature switch 8 blue/green 1 mm2
LCP > exhaust temperature switch 8 blue/rose 1 mm2
DDC > fuel valve solenoid 9 green 1,5 mm2
DDC > stop solenoid 20 pink 2,5 mm2
DDC > current measuring transformer 11 black 1 mm2
DDC > current measuring transformer 11 red 1 mm2
DDC > LCP 19 orange 1,5 mm2
DDC > LCP 12 black 1,5 mm2
DDC > LCP 14 red 1,5 mm2
DDC > LCP 16 red/green 1,5 mm2
DDC > generator AC output 33 brown 1 mm2
DDC > generator AC output 33 blue 1 mm2
LCP > battery charger winding generator 10 red 1 mm2
LCP > battery charger winding generator 10 red 1 mm2
DDC=Digital Diesel Control Unit
LCP=Local Control Panel

INFORMATION
14 May 2006 / WHISPER 3,5 / EN
2.5.14 Lay out control PCB
Fig 7: Lay out control PCB

INFORMATION
EN / WHISPER 3,5 / May 2006 15
2.5.15 Electrical diagram 230 V AC / 50 Hz
Fig 8: Electrical diagram 230V
EARTH AND NEUTRAL CONNECTED

OPERATION
16 May 2006 / WHISPER 3,5 / EN
3 OPERATION
3.1 GENERAL
The generating set is operational after full installation and
filling up with: fuel, engine lubricating oil and cooling liquid,
filling the starter battery with acid, connecting the battery
to earth and connecting the digital remote control panel.
1 Filling cap
2 Minimum oil level
3 Maximum oil level
Fig. 9:
3.2 OPERATING INSTRUCTIONS
3.2.1 Summarised operating instructions (daily
use)
Routine "pre-start" checks:
1 Check oil level (refer to fig. 9).
2 Engine cooling system (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 MASTERSWITCH 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 MASTERSWITCH 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 (i.e.
30% of 3 kW is approx. 1000W) 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 230V power source, if available. If
a Masterswitch is installed, this is done automatically.
3.2.2 Extended operating instructions
Check when starting the first time or after a longer period
of rest:
1 If there is any damage caused by transport or
installation.
2 Check if 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.
2 Check sea water cocks. Do not forget the valve of the
water outlet in case of a water/exhaust gas separator.

OPERATION
EN / WHISPER 3,5 / May 2006 17
3 Check the water strainer.
4 Check for leaks.
5 Regularly check the siphon vent in the cooling water
supply.
6 If no MASTERSWITCH is used: Switch main Power
Source Selector switch to "OFF" or switch off all
devices.
7 Switch 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 Whisper 3,5 can even be started with an almost
discharged battery using the cylinder compression release
handle. The engine can then be rotated easily ("turned
over") as the valves are opened i.e. in the decompression
position.
You can also use the decompression handle to readjust
the valve clearance and to fill the cooling system with anti
freeze for conservation in winter time.
A restart protection prevents starting the engine when it is
already running, which could cause damage.
In the event of starting problems (numerous
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, because 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
damaging the impeller.
Water in the cylinder will cause serious damage to the
engine. For instance; a bent piston rod or a cracked
cylinder head. In fact water in the cylinder is the main
cause for engine damage in pleasure craft.
Checks once the generator is in operation:
1 Check for abnormal noise or vibration.
2 Check the voltage.
Fig. 10: Decompression handle
3 Check 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.
4 Power source selector switch (off/shore
power/generator power). Switch to power source
generator. If a MASTERSWITCH is installed, this
operates automatically.
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 run 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!

OPERATION
18 May 2006 / WHISPER 3,5 / EN
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 80% or the rated generating set’s maximum load.
Please note this when switching on your electrical devices!
Nevertheless, the Whisper 3,5 is designed so as not to
overheat, even under extreme conditions.
Do not run the generator for very long periods at no load
or at very low load. When this is necessary do load the
generator at least one hour in 10 hours for minimum 70%.
Long term running at too low load will cause the exhaust to
be choked by carbon.
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:
1 Avoid 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
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
electric motors, compressors (in refrigerators or air
conditioners etc.).
2 Press the STOP button.
3 Close the inlet sea water cock.
4 Switch to an other 230V 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
button, otherwise it will drain the start battery

MAINTENANCE
EN / WHISPER 3,5 / May 2006 19
4 MAINTENANCE
4.1 ALTERNATOR
The alternator does not require any maintenance. Periodic
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
measurement 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 generator 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 carried out when the en-
closure is open. For repairs we recommend to take out the
generating set to a workshop. The enclosure can be
completely removed by taking out the bolts form the
aluminium bars below the bottom of the capsule.
When oil and dirt have gathered in the enclosure
measures have to be taken to avoid spilling oil and
polluting the environment.
The first service on the engine should be carried out after
25 hours of its life. This also applies after a major over-
haul. In the first 25 hours the engine should receive
special attention:
Long periods of light or no load running in the first 25
hours may lead to cylinder glazing and high oil
consumption.
For the same reason it is of the greatest
importance to use the right oil specification
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 Whispers are self
bleeding. Push the start button activating the electric
system and activating the fuel pump. When more time is
needed to bleed, push “start” and hold on the local control
panel (so not on the remote panel). Hold as long as
necessary to bleed the system.
Fig. 11: Self bleeding fuel lines
4.2.3 Valve clearance
Tightening torques, refer to § 5.4.2.
When the engine is in cold condition both valves should
have a clearance between 0.14 and 0.18 mm. The
adjustment has to be done at T.D.C. of the compression
stroke. Using a pocket light one can check the position of
the flywheel (refer to picture 12). By using the
decompression handle one can crank the engine easily
with a screwdriver to put the marks in line. Confirm that the
valves do not move up or down when the crankshaft is
turned about 20 degrees in normal and reverse direction of
rotation. If the rocker arms move the piston is on the
T.D.C. of the intake or exhaust stroke. In such a case turn
the crankshaft 360° in the direction of engine rotation
again. The piston is now at T.D.C. of the compression
stroke. After readjustment one should crank the engine for
20 rotations and check the valves again.
Fig. 12: Valve clearance

MAINTENANCE
20 May 2006 / WHISPER 3,5 / EN
4.2.4 Replacing fuel filter
Filter change depends on contamination of the fuel, but
should be done however, at least every 1000 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 Cleaning oil strainer
The oil strainer is behind a plug on the bottom of the
engine. In the strainer is a magnet to catch the metal parts
which are in the lubricating oil. Once per 1000 hours or
when the oil is contaminated one can clean the strainer by
washing it with petrol or a solvent. A green rubber plug in
the capsule gives access to the strainer. Before taking out
the plug one should sump the oil. Use tissues to avoid
spilling oil in the capsule.
4.3 REGULAR MAINTENANCE
CHECK DAILY:
•Oil level (see fig. 13) Take care the oil level is
never below the mark.
•Hoses for loose connections or deterioration.
•Water inlet filter.
1 Filling cap
2 Minimum oil level
3 Maximum oil level
Fig. 13:
AFTER FIRST 50 HOURS:
•Change oil.
Have the engine run until it is on temperature and
stop it. Drain oil by the sump pump into a suitable
retainer and fill up with fresh oil. Start the engine
again and have it run for 5 minutes. Stop the
engine again and pause for a few minutes to let
the oil gather in the crankcase. Check the level
again and add oil when necessary.
•Check and tighten nuts, bolts, and unions, paying
particular attention to the fuel system.
•Check the valve clearance.
•Observe the exhaust at the normal full load. The
exhaust must be free from soot. Do not allow the
engine to run with a dirty exhaust without
investigating the cause as this may result in an
expensive breakdown.
•Check siphon breaker valve or air vent on a
regular basis. When the air vent it not working
properly the engine can fill up with water by
siphoning. Water in the combustion chamber
causes serious damage to the engine.
EVERY 150 HOURS:
•Change oil.
•Check the battery acid level.
•Check battery terminals for corrosion
•Check impeller raw water pump (durability
depends on the purity of the sea water. In sandy
water and warm water wear will increase). When
replacing the impeller the gasket between the
pump case and the cover should be replaced as
well. So when ordering a spare impeller order a
gasket as well.
Remove the cover to get access to the impeller.
Remove the old impeller with the help of two
screwdrivers. Install the new impeller and add
some grease. Turn the blades in the direction of
rotation of the pump i.e. anti clockwise looking at
the impeller.
EVERY 300 HOURS:
•Replace the impeller of the raw water pump.
•Check valve clearance.