WhisperPower W-TG 3000 User manual

USERS MANUAL
W-TG 3000
- 3000 RPM -
Portable Diesel Generating set 230V / 50Hz
V1 June 2012
Art.nr. 40200021
WHISPER POWER BV
Kelvinlaan 82
9207 JB Drachten
Netherlands
Tel.: [phone]
Fax.: [phone]
www.whisperpower.eu

EN / W-TG 3000 / June 2012 2
CONTENTS:
1INTRODUCTION..........................................................................................................................................................3
1.1 General ..........................................................................................................................................................3
1.2 Service and maintenance ...............................................................................................................................3
1.3 Guarantee......................................................................................................................................................3
1.4 Liability...........................................................................................................................................................4
1.5 Identification...................................................................................................................................................4
1.5.1 General..........................................................................................................................................4
1.5.2 Identification plate..........................................................................................................................4
2INFORMATION............................................................................................................................................................6
2.1 Safety.............................................................................................................................................................6
2.1.1 General..........................................................................................................................................6
2.1.2 Electrical safety..............................................................................................................................6
2.1.3 Refueling precautions.....................................................................................................................6
2.1.4 Installation......................................................................................................................................6
2.1.5 Operation.......................................................................................................................................7
2.1.6 Fire and explosion..........................................................................................................................7
2.1.7 Chemicals......................................................................................................................................7
2.1.8 Other safety precautions ................................................................................................................8
2.2 Transport, lifting and storage ..........................................................................................................................7
2.3 The W-TG 3000..............................................................................................................................................8
2.3.3 Documentation...............................................................................................................................8
2.4 Components...................................................................................................................................................9
2.4.1 Main components to identify...........................................................................................................9
2.5 Technical Information ...................................................................................................................................10
2.5.2 Engine .........................................................................................................................................10
2.5.5 Alarms and shut down..................................................................................................................10
2.5.6 Control.........................................................................................................................................10
2.5.10 Fuel specification .........................................................................................................................10
2.5.11 Oil information..............................................................................................................................10
2.5.13 Technical data..............................................................................................................................11
3OPERATION..............................................................................................................................................................12
3.1 General ........................................................................................................................................................12
3.2 Operating Instructions...................................................................................................................................12
3.2.1 Summarised operating instructions (daily use)..............................................................................12
3.2.2 Extended operating instructions....................................................................................................12
4MAINTENANCE.........................................................................................................................................................14
4.1 Engine..........................................................................................................................................................14
4.2.1 Preliminary instructions ................................................................................................................14
4.2.3 Valve clearance............................................................................................................................14
4.2.4 Replacing fuel filter.......................................................................................................................14
4.2.5 Replacing oil filter.........................................................................................................................14
4.2 Regular maintenance..................................................................................................................................15
4.3.1 Maintenance schedule..................................................................................................................15
4.3.2 Putting out of service....................................................................................................................16
5TROUBLE SHOOTING..............................................................................................................................................17
6SPARE PARTS LIST.................................................................................................................................................18

EN / W-TG 3000 / June 2012 3
INTRODUCTION
GENERAL
The W-TG 3000 Portable Diesel Generating set is
manufactured and marketed by WhisperPower.
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
reserve 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.
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.
GUARANTEE
WhisperPower 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 correct 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
for the North of the Netherlands number 01120025 and
are available on request. The guarantee period is two
years, limited to 1000 running hours. Some aspects of our
guarantee scheme are given here in more detail:
Guarantee period 1000 running hours or 24 months
whichever occurs first. Warrantee does not cover failures
that are caused by misuse, neglect or a faulty installation.
DAMAGE CAUSED BY THE INGRESS OF
WATER IS NEVER COVERED BY
GUARANTEE
For Example : Neglect
When one find serious damage after weeks of neglect
guarantee claims will not be honoured.
WhisperPower cannot be held responsible for damage
caused by the unattended running generator.
Warranty means that faulty parts are repaired or replaced
free of charge. If necessary the whole generator unit will
be exchanged.
Travel expenses and travel hours are not covered.
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 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.
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.
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.

EN / W-TG 3000 / June 2012 4
Should work take place, which is not in
accordance with the guidelines, instructions
and specifications, 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!
LIABILITY
WhisperPower 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. WhisperPower does not accept
liability for damage due to use of the generator, possible
faults in the manuals and the results thereof.
IDENTIFICATION
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.
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.

EN / W-TG 3000 / June 2012 5
1 RATED OUTPUT
The identification plate gives the nominal maximum
continues load in kVA (= kW). The power should
never exceed the nominal power as shown on the
identification plate. Power is rated at an ambient
temperature of 40°C.For higher temperatures the
generating set has to be derated.
2 VOLTAGE shows the nominal voltage.
This voltage should be within the specified tolerance
at the nominal frequency.
3 FREQUENCY is shown in Hz and is determined by
the speed of the engine (RPM). 50 Hz correlates with
3000 rpm.
.
4 POWER FACTOR
When calculating a load one should always take into
account the power factor or cos. phi of this load.
5 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 identification plate are also
some basic features of the set:
6 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.

EN / W-TG 3000 / June 2012 6
INFORMATION
SAFETY
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.
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.
Warning signs indicate parts which could be
live.
Installation
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 fuel pipes etc. Refer to the
installation manual.
Refuelling precautions
Do not refuel indoors or in a poorly ventilated
area.
Be sure to stop the generator before refuelling.
Do not overfill the fuel tank.
If fuel is spilt wipe it away carefully before starting
the engine.

EN / W-TG 3000 / June 2012 7
Operation
External moving parts are covered by the soundshield and
therefore the W-TG 3000 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.
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.
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.
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 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.
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
After transporting the generating set check for
damage before installation.
Long term storage can have detrimental effects
on the engine. The engine should be put through
an engine preservation procedure. (Refer to the
maintenance chapter)
After removing the generating set from long term
storage perform an insulation check.
While the battery is stored it should be recharged
every 12 weeks.

EN / W-TG 3000 / June 2012 8
Other safety precautions
Where to use the generator.
Use it more than 1m away from buildings or any
other facilities
When using the generator.
Do not tip or move.
Do not cover it with a box or fence around it.
Never unscrew the dipstick when using the
generator set, or else scald will be caused by
ejective oil.
Do not touch the generator in the rain. And also
do not splash water or touch with a wet hand.
To avoid an electric shock, ground the generator
from the ground terminal.
Avoid using the generator at a place where the
ground is not firm.
Never connect the generator to the wiring of a
power company.
The W-TG 3000
Documentation
Included in the delivery is:
This users manual (number: 40200021)
However in this manual there is a list of important parts for
maintenance and spare parts as well as a chapter on
maintenance and problem solving.

EN / W-TG 3000 / June 2012 9
COMPONENTS
Main components to identify
1. Starter key
2. Volt meter
3. 230V breaker
4. 230V connection
5. 12V connection
6. Ground connection
7. Low oil alarm indicator
8. Fuel tank
9. Front door
10. Back doors
11. Muffler
12. Fuel filler cap
13. Fuel meter
14. Identification plate
15. Air filter
16. Engine speed lever
17. Oil filter
18. Oil drain plug
19. Oil filler cap/dipstick
20. Engine stop lever
21. Recoil starter
22. Fuel pump
23. Oil sensor
24. Fuel injection limiting bolt
Overview W-TG 3000

EN / W-TG 3000 / June 2012 10
TECHNICAL INFORMATION
Engine
The W-TG 3000 generating set is based on 178 FA 1 cylinder 4 stroke diesel engine. The engine is directly injected. The
engine is air cooled.
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 is one function guarded: low oil level.
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.
Control
The generating set can be operated by a key on the panel of the generator. To start the generator you have to follow the next
procedure.
Open the fuel cock.
Turn the starting key clockwise to the “START” position.
Remove your hand from the key as soon as the engine starts.
If the engine doesn’t start after 10 seconds, wait a while ( for about 15 seconds)
Before attempting to start again.
Fuel specification
The engine must only be used with diesel fuel oil which conforms to the standards for use in modern diesel engines. Keeping
the fuel free from water and contaminants is of the utmost importance.
Oil information
1 Specification:
The oil must be suitable for oil changes as specified in the maintenance chapter. The engine must be run on heavy duty
lubricating oil meeting the requirements of API class CC or CD.
It is very important to use the correct oil specification. Very often local oil suppliers recommend a higher class, because they
assume that a higher class is allowed. This is not the case. One should not follow these recommendations.
Using the wrong specification will cause high oil consumption.
2 Oil viscosity:
We recommend a multigrade oil 10W40.
3 Oil capacity:
The content of oil including the oil filter is 1.1 l.
Do not overfill with lubricating oil as this may have a detrimental effect on engine performance.

EN / W-TG 3000 / June 2012 11
Technical data
GENERAL
Model
W-TG 3000
RPM
3000
Engine
Air cooled direct injection diesel engine
Number of cylinders
1 cylinder 4 stroke
Displacement
306 cm3
Bore X stroke
78x64 mm
Continuous power engine
5 HP
Cooling system
Forced air cooling
Fuel tank capacity
12.5 L
Running time at full tank
12 hours @ 1 kW
Control
AVR
ELECTRICAL SPECIFICATIONS
Output voltage
230VAC 12VDC/8.3 A
Output rating
2.8 kVA at powerfactor cos phi = 1.0
Maximum power
3 kVA
Maximum current
13A
Nominal speed
3000 rpm
Nominal frequency
50 Hz
Voltage regulation:
AVR
MECHANICAL SPECIFICATIONS
Dimensions hxwxd
630x480x720 mm
Colour
Black and white
Weight
106 kg including battery
Max. installation angle
20 degrees
Standard supplies
Automatic air bleeding mechanism, AC Voltmeter, AC circuit breakers, additional
DC output, DC over current protection, extra large fuel tank with fuel gauge, large
capacity exhaust silencer, starter battery

EN / W-TG 3000 / June 2012 12
OPERATION
GENERAL
The generating set is operational after full installation and
filling up with: fuel, engine lubricating oil, filling the starter
battery with acid, connecting the battery to earth.
OPERATING INSTRUCTIONS
Summarised operating instructions (daily use)
Routine "pre-start" checks:
1 Check oil level (refer to fig. 8).
2 Switch on battery switch (when installed).
3 Fuel valve: open.
Starting:
Make sure that the engine speed lever is in the “RUN”
position.
Turn the starter key to the start position, remove your
hand from the starter key when the engine is on.
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.
2 Check for leaks.
.
3 Switch on the battery switch.
In operation checks:
1 Check for abnormal noise or vibration
2 Check the voltage
3 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 Turn the starter key to the off position. Do not stop the
engine with the decompression lever.
3 Close the fuel cock.

EN / W-TG 3000 / June 2012 13
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!
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).
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.

EN / W-TG 3000 / June 2012 14
MAINTENANCE
ENGINE
Preliminary instructions
All regular maintenance can be carried out when the
enclosure is open. When oil and dirt has 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
20 hours of its life and after a major overhaul. In the first
20 hours the engine should receive special attention:
Long periods of light or no load running in the first 20
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.
Valve clearance
When the engine is in cold condition both valves (inlet and
outlet) should have a clearance between 0.10 and 0.15
mm. The adjustment has to be done at TDC.
Replacing fuel filter
Filter change depends on contamination of the fuel, but
should be done however, at least every 300 running hours.
A clogged filter results in a lack of output of the generating
set.
Replacing oil filter
The oil filter is in front of the service side. Replacement
has to be executed according to the schedule in this
manual. Drain the oil using a sump pump and put some
tissues under the filter.

EN / W-TG 3000 / June 2012 15
REGULAR MAINTENANCE
CHECK DAILY:
Oil level (see fig. 13)
Make sure that the oil level is
never below the mark. Do not
add oil when the level is still
above the mark
1 Maximum oil level
2 Minimum oil level
Fig. 13
Maintenance schedule
CHECK DAILY:
Hoses for loose connections or deterioration.
When the generator set runs less than 100
hours a year the oil should be changed yearly.

EN / W-TG 3000 / June 2012 16
Putting out of service
When not using the generating set for a longer period it is
recommended to execute an engine preservation
procedure.
1 Clean the engine.
2 Drain the fuel tank and fill with preservation diesel.
Start the engine and run the engine warm.
3 Drain the hot engine oil and refill with preservation oil.
4 Remove the plastic plug on the rocker arm cover and
add about 2cc of lube oil, put the plug back into place.
5 Push the decompression lever to non compression
position and turn around the engine for about 2-3
seconds with the key switched to start.
6 Pull the decompression lever up and pull the recoil
starter up slowly until it feels tight. This closes the
valves and prevents from forming rust.
7 Disconnect the battery and store it in a dry place free
of frost and charge it regularly.
8 Close inlet- and outlet openings with tape.
9 Protect the generating set against the influences of
bad weather conditions.
This method of preservation will be sufficient for 6 months.
Repeat steps 1,3,4 and 9, every 6 months. Change oil
before using the engine again.

EN / W-TG 3000 / June 2012 17
TROUBLESHOOTING
If there occurs any trouble starting the generator make
sure that you check all of the following points in the
schedule below.

EN / W-TG 3000 / June 2012 18
SPARE PARTS LIST
No.
Art no.
Description
Qty.
1
40290020
Starter battery W-TG3000
1
2
40401329
Air filter element
1
3
40401398
Oil filter included O-ring
1
4
40402074
Fuel oil filter gasket
1
5
40402075
Filter element assy.
1
6
40222204
WPL- 10W40 GENERAL

EN / W-TG 3000 / June 2012 19