: whisper power - Stromgenerator M
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1. 12V 55Ah Integrated in WP PMG Oil temperature coolant exhaust temperature M GV4 Piccolo June 2015 EN TECHNICAL INFORMATION ALTERNATOR SPECIFICATIONS Type Permanent Magnet Alternator PM Model 16Nm 5kW at 3000rpm inner rotor air cooled Nominal output 420V line line 9 2A 400Hz 3 phase star configuration 533Hz Rotor stator 105 419V line line at 1000 4000rpm 133 533Hz 24 coils 16 poles Insulation grade Class F max 155 C 3 6kV 500Hz Peak efficiency 94 Cooling Forced Forced air Rotor balancing ISO 1940 G2 5 SOUND SHIELD SPECIFICATIONS Material Polyester with inner bitumen layer Insulation 25mm layer Audible noise level open field 54dBA at 7 meter 65dBA at 1 5 meter POWER MODULE SPECIFICATIONS Model WP PMG Power Module Genverter 4kW frame 1 Input voltage current frequency 360 440V 11A up to 500Hz 3 wire L1 L2 L3 Output voltage current frequency 230V 16 5A 50Hz 3 wire line Neutral PE Voltage Total Harmonic Distortion nominal load gt 3 THD Efficiency Peak 95 average 93 Cooling Forced air cooling Generator control Local start stop local read out module Optional generator control WhisperPower DDC auto Start Stop compatible Standard remote control LED te pa LED remote panel 10 mtr cable 9 RJ12 connectors COMPLIANCE Directives EMC 2004 108 EC EM Standards EN 55022 emission EN 61000 3 2 harmonics EN 61000 4 11 EN 61000 3 3 voltage fluctua2. 4 Switch on the battery switch when installed 5 Make sure the fuel valve is open Figure 6 Speed regulator M GV4 Piccolo June 2015 EN 13 OPERATION STARTING ROUTINE AND CHECKS inv Failure O press O temp Exh temp Figure 7 WP PMG local panel Start the WP_GV4 Piccolo 1 Push the START button on the WP PMG local panel Figure 7 and hold for two seconds to initiate the full automatic starting procedure As a result the electric system is activated You can monitor the procedure on the remote control display The first time starting up or after running out of fuel it ere EF ey 4 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 When ramping up rpm the engine will probably produce some smoke After stabilizing on the right rom for the load the exhaust should be free from soot STOPPING ROUTINE How to stop then WP GV4 Piccolo Genverter 1 Switch off all electrical devices consumers If the GV4 Piccolo 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 PMG STOP button Figure 7 and hold for 2 seconds 3 Switch to another AC power source if available 4 3 2 Extended operating instruc
3. Genverter even more silent The oil is will start the engine automatically Pushing the STOP button cooled by a relatively small heat exchanger again hold two seconds will stop the engine and the electrical system will be deactivated The heat exchanger is standard integrated in the sound shield canopy but can be placed separately not standard DIGITAL DIESEL CONTROL SYSTEM either incorporated in the One could use the hot oil for generating heat CHP Combined ae WP PMG or integrated in the DDC control box Heat Power generation For this a cation additional The engine is directly injec exhaust emission standa manage both the Further details are in th inverter operation 3 1 2 AC Permanent Magnet Alternator DDC provides options for the Piccolo user to realize advanced The Three Phase Permanent Magnet Alternator is incorporated settings and functionality Change DDC settings by means of the Kn E in the flywheel and has a very high efficiency of 94 or higher DDC remote control panelt beable to operate the WP GVA because of the very high tech super magnets that are used The Piccolo in variable speed or automatic mode output of the power from the alternator will be between 250V 300Hz and 400V 500Hz depending on the engine speed As the Refer to Section 4 2 and the DDC operational manual for efficiency is very high little cooling is needed The alternator detailed instructions i
4. and wiring Sp aw 12 M GV4 Piccolo June 2015 EN ED OPERATION 4 OPERATION 4 1 General 4 2 Variable speed mode The GV4 Piccolo is operational after full installation and filling REENER DECRETEN JEDE SEEDS dev fuelend engine lubricating oil andsubsenuentiy means of the DDC remote control panel Refer to the DDC a operational manual for detailed instructions connecting the battery and digital remote control panel p Fill with lubricating oil twice to allow the heat exchanger to get In variable speed mode the engine will start when the starting filled with oil This is done by filling up with oil first run for 60 button is pushed The speed will adapt to the load When an seconds and then stop the engine and fill up again additional load will be switched on the engine will speed up To bees de id that the engine will n rovide enough r to speed When checking the oil level inside the lubricating oil reservoir AVO TRAE NE ENEINE WILNOY Provide ENGUEN POWE tO Sp simply dip the dipstick into the oil without screwing the dipstick HP A NE AENEAN E ARENE Mini abEneIne epee has to be set to a minimum worst case level from which the into the sump engine will be abel to speed up again Fi ing ca Example When the engine is running at no load or almost no load at 2500 rpm and a 3 kW load e g an air conditioner with an inrush current for motor starting of 4 x nominal power is switched
5. batteries e Keep a fire extinguisher on hand 2 1 10 Chemicals Fuels oils coolants and battery electrolyte can be hazardous 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 e The alternator windings tend to condense To minimize condensation store the Genverter in a dry and warm storage area While the battery is stored it should be recharged every 12 weeks 2 3 Features 2 3 1 General The WhisperPower Genverter combines a small oil cooled diesel engine a Permanent Magnet alternator and an Inverter making variable speed possible Variable speed means that the engine will operate at low rpm when little power is needed and at high speed up to 3600 rpm when a high output is demanded Because of variable speed the unit operates much more economic less fuel consumption the life time is much longer than generators that run constantly at high speed and the noise is much lower when running at low speed 2 3 2 Construction The Genverter incorporates a diesel engine which has a permanent magnet alternator in the flywheel The engine is mounted on a steel base frame and mounted securely on a double set of anti vibration mounting pads in a sound attenuated canopy The output of the power from the alternator will be about 300V 400Hz and 400V 500Hz lubricating oil e Engines may be fitted with seals or O rings manufact
6. environmental contamination Check the air filter at least every 400 running hours The foam around the filter element can be cleaned by compressed air Do not use solvents to clean the foam The filter cannot be cleaned and must be replaced Access to the filter can be obtained by unscrewing the wing nut and pulling the engine towards the service side The filter can now be replaced 5 4 Regular maintenance 5 4 1 Changing oil and cleaning the oil strainer In practice it will not be possible to change all oil in the system because some oil will be left in the cooling system Therefore we recommend changing the oil twice especially at the end of break in Have the engine run until it is on temperature and stop it Drain oil by using a vacuum pump as commonly used in garages Refill the engine with oil start the engine and have it run for 5 minutes Stop the engine and pause for a few minutes to let the oil gather in the crankcase The oil strainer can be found left below on the service side Drain the oil again and put some tissues under the oil strainer cap before removing it Take out the strainer element and clean MAINTENANCE 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 engine and irregular running 5 4 6 Air filter element The W GV4 Piccolo is standard supplied with an air inlet
7. 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 without prior notice Whilst every effort is made to ensure the accuracy of the 1 4 Liability WhisperPower does not accept responsibility for damage injuries or casualties which are the result of operation of the Genverter 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 Genverter possible errors in the manuals and the results thereof 1 5 Identification 1 5 2 Identification plate All required identification data are on the identification plate providing the following information The identity of the Genverter is given by the SERIAL NUMBER POWER The identification plate gives the maximum 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 load should never exceed the nominal power as shown on the identification plate Power is rated at an ambient temperature of 252C For higher temperatures the Genverter has to be de rated according to the directions in this manual For service and mainten
8. on the engine will probably not be able to ramp up the rpm In this case the low speed setting has to be higher Maximum oil level possibly 2800 rpm However when load steps of only 1 kW are switched on one after another a low speed setting at 2500 he rpm will be OK The optimal low rpm setting can be established MERE SME by trial and error L N 4 3 Operating instructions Figure 5 Oil dipstick ADJUSTING GENERATORIFRE NCY starting the WP GV4 Piccolo The Piccolo operates on fixed speed Use the speed regulator refer to Figure 6 to manually adjust speed according preset 1 Check oil level speed ranges as documented in the specifications if preferred The GV4 Piccolo Genverter switches off in the event of Untighten the regulator move downward to adjust speed and insufficient oil pressure tighten again Even when the oil level is too low the oil pressure can be high enough not to trip an alarm Do not run the engine with the oil below the lowest mark because a smaller volume of oil will become contaminated considerably quicker than a larger volume Also the cooling can be affected 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 leakages 3 Switch to power source selector switch to OFF or switch off all consumers in the usual way
9. remove the AC supply remove the connection to the batteries e be sure that third parties cannot reverse the measures taken If maintenance and repairs are required use original spare parts only Always consult the manual before carrying out maintenance 2 1 5 Electrical safety Warning signs indicate parts which could be live e Check all wiring at least once a year Defects such as loose connections burned cables etc must be repaired immediately e 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 e Connection and protection must be done in Circumstances could make it also necessary to take additiona measures Be aware of wet conditions and hazardous environments caused by explosive gases etc 2 1 3 Organizational measures The user must always e have access to the user s manual be familiar with the contents of this manual This applies in particular to this chapter Safety Guidelines and Measures 2 1 4 Maintenance amp repair WARNING When service has to be carried out while the engine is running be aware of moving parts M GV4 Piccolo June 2015 EN acc standards 2 1 8 Operation There are no external moving parts like fans and V belts The hot parts of the engine are covered by the sound shield and therefore the M GV4 P
10. Air in the fuel pipes e Choked fuel filter e Disturbances on the electrical system user side e Faulty fuel lift pump e Choked air filter e Lack of air e Choked exhaust system exhaust blocked e Faulty actuator e Blocked injector e Wrong valve clearance e Lack of fuel advice Repair by WhisperPower service Fill up with fuel or replace by better quality Bleed air from fuel system refer to section 5 2 2 Check fuel filter and replace if necessary Check whether the equipment using power has higher starter voltage demand If not contact WhP service center Check and repair or replace Check the air intake Replace air filter if necessary Check the exhaust piping Contact WhisperPower service department for advice necessary Replace faulty parts Contact WhisperPower service department for advice Have the injector tested and cleaned if necessary Adjust valve clearance Check fuel supply system fuel pump and filter Clean if necessary M GV4 Piccolo June 2015 EN PROBLEM Engine speed drops Engine does not stop on command Engine exhaust smokes Engine starts but stops after 10 up to 30 seconds M GV4 Piccolo June 2015 EN CAUSE e Genverter overloaded e Fuel problem e Too much lubricating oil e Lack of intake air e Choked exhaust system exhaust blocked e Faulty actuator e Defective alternator windings or other e Damaged engine e Fuel solenoid is no
11. An installation manual number 40200831 e ADDC operating manual no 40200801 e A DDC quick reference guide no 40200142 The user s manual contains a list of important maintenance and spare parts as well as a chapter on maintenance and problem solving Manuals in other languages are available on request M GV4 Piccolo June 2015 EN TECHNICAL INFORMATION 250V 3 TECHNICAL INFORMATION 3 1 Parts and relevant functions 240V 230V 220V The W GV4 Piccolo Genverter is a very advanced high tech variable soeed power supply system It combines new technologies from different fields such as engine technology PM alternator technology and inverter technology 3 1 1 Engine The engine used in the Genverter is developed by Inv Failure WhisperPower and manufactured exclusively for Oil press WhisperPower The concept is unique as the engine is fully Oil temp cooled by oil The same oil that is used for lubrication is also Exh temp used for cooling However the lubrication circuit is separate from the cooling circuit that has its own pump Figure 1 WP PMG control panel As the cylinder and cylinder head are surrounded by oil the noise of the engine itself is extremely low The oil cooling By pushing the START button on the PMG control panel refer makes it possible to apply the engine in an almost fully enclosed to Figure 1 for two seconds the control system is activated and canopy what makes the
12. E E EAEE E EEOAE nee A eee ee 16 5 3 3 NI CE essa E E E N A non 16 5 3 4 Replacing TUG TTET css suscccunstaxceteevuneassenacsedasusgensetancetemanuosassentce Saaasautuclansetaneanestassaasehsueavacdecidessiesdcourtessstectsuteed 16 5 3 5 cleanin OIS CORRE ee SEEE ES AEAEE 16 5 3 6 PN TION CLO a i AE A E EE A A S A A A EE babe 17 5 4 Regular Maint tenane E nine ed Done a ETAS 17 5 4 1 Changing oil and cleaning the oil strainer sise 17 5 4 2 FMS the E EE E ne N EE SAAT A N dd A A te 17 2 M GV4 Piccolo June 2015 EN CONTENTS 5 4 3 Draining Water from the fuel tank cicisiicsasisdocsdciesserecdsdeninedsinadenisbersdabeaveianseeatiavensdedengeeeeiivdandeiaeiegeaadeinsaadaniabacsas 17 5 4 4 Replacing the coolant pump impeller siennes 17 5 4 5 Replacing the fuel filter nano nnenoer venen eere enenrrrvenenersennnnervenenensersennersesvanesseennnserseensensssnnnsensennsenn 17 5 4 6 PI WU E E a a oO ed ee nn 17 5 4 7 Checking hoses and electrical connections ss 17 5 4 8 Retightening cylinder head bolts and adjusting valve clearance anne oonnsnesrnsnensennerenn versn ersenensvens 17 5 5 PUR Ao Or SEN E a a a ana be ete ee na ie mn le 18 6 TROUBLESHOOTING icociconiconstonscecacensscnsecnsscnsvonesccatoasseaatosavecatvacsncosesoensoeucesecatuceuececpesaeccpencececeaecinecesenesodusacenstexsnonstenieonttonseeuawens 19 6 1 GEen T PR vaca ea nates ths wees nennen nakende ten E Salens entente 19 6 2 Alt rnaton electrical fanlle n
13. GV4 No 41002005 41002006 41002055 41002065 49002005 49002006 Issuer s name WhisperPower BV Issuer s address Kelvinlaan 82 NL 9207 JB Drachten Object of the declaration The object of the declaration described above is in conformity with the requirements of the following Directives and standards as applicable Document Title 2004 108 EC Electromagnetic Compatibility Directive EN 61000 3 2 2014 Electromagnetic compatibility EMC Part 3 2 Limits Limits for harmonic current emissions equipment input current lt 16 A per phase EN61000 6 1 2007 Electromagnetic compatibility EMC Part 6 1 Generic standards Immunity for residential commercial and light industrial environments EN 61000 6 2 2007 Electromagnetic compatibility EMC Part 6 2 Generic standards Immunity for industrial environments EN 61000 6 3 2007 A1 2011 Electromagnetic compatibility EMC Part 6 3 Generic standards Emission standard for ial commercial and light industrial environments 2006 95 EC EN 60950 2000 2004 26 EC ons Directive 2006 42 EC f EN 842 1996 A1 2008 Safety of machinery Visual danger signals General requirements design and testing ISO 12100 2010 Safety of machinery General principles for design Risk assessment and risk reduction The machinery is incomplete and must not be put into service until the machinery into which it is to be incorporated or the vessel into which it is to b
14. TC800E0Y OU HY USER S MANUAL M GV4 Piccolo High efficiency 4kW Genverter for marine use WHISPERPOWER BV Kelvinlaan 82 9207 JB Drachten Netherlands Tel 31 512 571550 Fax 31 512 571599 www whisperpower com V1 1 June 2015 CONTENTS Contents 1 DOT 16 5 UT en j Le LPS es sce chen cane etwas eee es eee ee 4 1 1 GOTO EEE ZE 4 1 2 AE EIN DEE E EAN I E A E A E O I IA E AO E T A dte 4 1 3 GUN LE ET A A EE cc cin ace T E ET E E O ee E E A T AEE 4 1 4 Ee en 4 1 5 Wende ON TEN 4 1 5 2 Identification plate unsun er sernenrserensnrrrsennnervensn erven ensnserenenenenvennnenveesnnerssnsnnersvennnervenenensnsennnsenens 4 2 INFORMATION ennn eeen 4 2 1 2 nannieb nantes 4 2 1 1 Wamings and Ss MDI das AEREE LE EEEE trente ananas cast eee me ons 4 2 1 2 GERO EE TE E E ETE A P AEA E E ENEA T A TE A E E A TE TT 5 2 1 3 Oksana ten all Mea SU SS are ee EE ra ed OEE die co de 5 2 1 4 Maintenance amp repai aesir a EN AA NE 5 2 1 5 EE Al SOL EE E E A EE EEE one 5 2 1 8 D EENE PN 5 2 1 9 Fire and SXPIOSION cseccccccssseccceeecececeeeeccesueseceesauseecceaeeeeeesseeseceseeesseeeseaseeeesaeeeeeessusecesseeneeeeeeuaeeesseeseeeesnseeeaas 6 2 1 10 RSR a EEEE E EA A E E aetna sash T 6 2 2 WE NS OPE MUNE VS CON 87 12 Rn 6 2 3 A a a eceeeoneeaes 6 2 3 1 GERO ic E ESA AT EEE EA A O EEE OE O AA TTI OE EE E E 6 2 3 2 CONS COT i E E A nections 6 2 3 3 COMORES EN 6 2 3 5 DOCUMEN AIO a de ea Gandi oo
15. ance one can appeal to the manufacturer or the dealers 1 3 Guarantee WhisperPower guarantees that this Genverter 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 Genverters are tested and inspected This Genverter s proper operation 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 does not cover failures that are caused by misuse neglect or a faulty installation WhisperPower cannot be held responsible for damage caused by the unattended running Genverter tification plate also shows the maximum CURRENT that is acceptable at the specified fr factor uency voltage and power DC VOLTAGE is the voltage of the starter battery OL e voltag y The approximate net dry WEIGHT is shown in kg This is without fuel oil cooling liquid packing and external installation equipment The CE symbol shows that the Genverter has been built according to European Community safety regulations Refer to EC Declaration of Conf
16. art CAUSE e Almost certainly this is a battery problem Display will indicate LOW BAT1 e Wiring system faulty e Starter broken e Engine lubricating oil too thick e Out of fuel or faulty fuel water in the fuel e Fuel solenoid is not opening no click can be heard e Fuel lift pump is not working e Air in fuel lines SOLUTION Check battery voltage Recharge the battery Inspect battery terminals and cables for a good electrical connection inspect for corrosion tattered wires etc During the normal starting process the battery voltage drops to 11V with a fully charged battery If the voltage does not drop during starting the electrical connection is faulty If the battery voltage drops lower than 11V then the battery has been discharged too deep Repair the starter motor Change oil using a lower viscosity grade Fill up with fuel or replace with better quality Check wire connections and circuitry to solenoid refer to Single Line Diagram Repair if necessary Check fuel filter and fuel lift pump clean or replace if necessary Bleed air from fuel system refer to maintenance o L ompressio se of dirty valves section tor Have the injector tested and cleaned if necessary O Contact WhisperPower service department for Engine runs irregularly 20 e Loss of compression by wear out or damage e Unsuitable or contaminated fuel e Lack of fuel e
17. ct values taking into account the power factor of the consumers When in doubt measure the power NJ ok d air filter e Exhaust blocked e Injector blocked e Loss of compression sticking or damaged piston ring e Wear out of cylinder e Overload directiy using an appropriate instrument Drain oil to the correct level Check air inlet openings clean air filter Check the exhaust system If necessary contact WhisperPower service department for advice Have the injector checked and if necessary repaired Have the compression measured If necessary contact WhisperPower service department for advice Clean or replace the rings Have the compression measured and have the engine overhauled Reduce the load 22 e Exhaust choked with carbon e Cooling circuit failure Clean heat exchanger Clean exhaust Contact WhisperPower service M GV4 Piccolo June 2015 EN TROUBLESHOOTING 6 4 Raw water pump Exploded view raw water pump 40201270 Replace impeller 50209013 and or gasket 50209012 in case of failure SOPOTE Schroejes mpelkerpamp RVS IEGE Fidel Wimpole Backing Plate 40201270 MCT EERE WF Hose iens RON Rig Or fel AAA a 1 Mec narcol Seal Washer RP ichonisol Leal Wose vectoriais voee OOOO E hd EEF A SLE FOR 6 5 Warnings Genverter must be shut off immediately if e unusual noise comes from Genverter e exhaust gases sudd
18. e installed has been declared in conformity with the provisions of the Directive We undertake to transmit in response to a reasoned request by the appropriate national authorities relevant information on the partly completed machinery identified above Signed for and on behalf of WhisperPower BV M Favot Chief Technical Officer Drachten November 10 2014 The technical documentation for the machinery is available from WhisperPower BV Kelvinlaan 82 9207 JB Drachten Netherlands Kelvinlaan 82 9207 JB Drachten Netherlands Tel 31 512 571550 Fax 31 512 571599 www whisperpower com info whisperpower com
19. elow SAE 10W SAE 20W SAE 10W 30 SAE 15W 40 SAE 20 SAE 30 SAE 40 20 C 10 C O C 10 C 20 C 30 C 40 C 4 F 14 F 32 F 50 F 68 F 86 F 104 F Figure 4 Viscosity chart It is very important to select the right viscosity Especially in cold conditions the viscosity of the oil should be low so the oil should be thinner to keep the oil pressure in the cooling system within acceptable limits OIL CAPACITY The content of the crankcase should be TECHNICAL INFORMATION COOLING OIL PRESSURE e Minimum at idle 149 kPa 1 5 kgf cm 21 psi e Normal at 3000 rpm 80 C 180 220 kPa 1 8 2 2 kgf cm 25 35 psi e Maximum cooling oil pressure is protected by an overpressure switch that will trip at 550 kPa 5 5 kgf cm 80 psi In cold condition the pressure can be higher but the alarm will be suppressed COOLING OIL TEMPERATURE e Maximum oil cooling temperature 120 C oil out to the cooler e Minimum oil temperature 70 C e Sump oil temperature should be between 80 C and 90 C for optimal performance 3 1 10 Oil cooling heat exchanger The M GV4 Piccolo engine is cooled by oil and not by cooling liquid The oil cooled heat exchanger of the M GV4 Piccolo is not ventilated The system is ventilated by the engine itself and no expansion tank is applied e including heat e Do not overfill with lubri detrimental effect
20. enly color dark e engine failure warning light is on 6 6 Service address If you cannot correct a problem with the aid of the trouble shooting tables contact your WhisperPower Service Centre or WhisperPower Netherlands for an extended service list Tel INT 31 512 571555 7x24 Hr service M GV4 Piccolo June 2015 EN 23 SPARE PARTS LIST 7 SPARE PARTS LIST We recommend the following spares for service and maintenance e Kit A parts for regular maintenance parts marked article no 40401170 e Kit B parts for maintenance spare parts all parts marked article no 40401171 ARTICLE NO DESCRIPTION 40209030 Fuel filter 50201160 Fuel lift pump 40401329 Air filter element 40401340 Oil strainer 50209236 Lube oil pressure switch 50209239 Cooling oil pressure switch 50209219 Temperature sensor 40401101 Battery charger 40401062 PCB Local control panel 40401150 Digital Diesel Control unit 40209102 Digital Diesel remote control panel 50212171 Fuses 15 Amps 50212170 Fuses 10 Amps 50212155 Fuses 5 Amps 50212154 Fuses 3 Amps 40401060 Wiring loom 50209136 Remote control cable 10 m including connectors 40401279 Valve cover gasket 40401221 Cylinder head gasket 40401392 Cylinder head gasket kit 40401391 Sealing ring seal kit 40401020 brass spindle 40401385 Injectorassembly A A l i 40401381 Fuel pump high
21. filter element Filter change depends on environmental contamination Check the air filter at least every 400 running hours The foam around the filter element can be cleaned by compressed air Do not use solvents to clean the foam The filter cannot be cleaned and must be replaced Access to the filter can be obtained by unscrewing the wing nut and pulling the engine towards the service side The filter can now be replaced 5 4 7 Checking hoses and electrical connections Visually check cooling hoses fuel hoses and electrical wiring paying particular attention to abrasion wear and corrosion Have items replaced when necessary 5 4 8 Retightening cylinder head bolts and adjusting valve clearance Both procedures have to be carried out with a cold engine Be sure to retighten the cylinder head bolts before adjusting the valve clearance First remove the valve cover it if necessary using tissue or white spirit Refill with fresh oil for the second time minutes stop pause for afew minutes check the level and add oil if necessary 5 4 2 Checking the be Check the battery terminals for corrosion and clean if necessary If an open lead acid battery is being used maintain the electrolyte level between UPPER and LOWER marks on the case If the battery has not got any level marks maintain the level 10 to 15mm above the cells Remove the filler caps and add distilled water when necessary 5 4 3 Draining water from the
22. fuel tank Remove the drain plug and allow any water and sediment to drain Drain at least 1 or 2 liters of fuel to remove the water and sediment 5 4 4 Replacing the coolant pump impeller When the impeller is replaced the gasket between the pump case and the cover should be replaced as well see also 6 2 3 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 anticlockwise looking at the impeller Refit the cover using the new gasket 5 4 5 Replacing the fuel filter Filter change is needed when the fuel is contaminated and as part of preventive maintenance at least every 400 running hours Before changing the filter clamp off the supply line M GV4 Piccolo June 2015 EN Loosen the bolts slightly remove the rocker assembly the rocker arms shaft and stays and then retighten the bolts to the specified torque inthe numerical order illustrated Tightening torques Cylinder head screws M9x1 5 47 to51 Nm Rocker arm bracket mounting M6 x 1 10 to 12 Nm Standard torque chart M6x1 0 M8x1 25 M10x1 5 Nm 10 8 1 0 25 5 2 9 49 0 4 9 Apply 80 torque when tightening bolts to aluminium alloy 17 MAINTENANCE Valve clearance When the engine is in cold condition both valves should have a clearance of 0 15 0 03mm The adjustment has
23. ith preservation oil rew plug on the cylinder cover and and store it in a dry place free of frost and charge it regularly 7 Close inlet and outlet openings with tape 8 Protect the Genverter against the influences of bad weather conditions This method of preservation will be sufficient for 6 months Change oil before using the engine again M GV4 Piccolo June 2015 EN 6 TROUBLESHOOTING 6 1 General If any problem should occur check basic conditions and examine all external wiring switch gear and circuit breakers Also check if measuring instruments give the correct value If in doubt measure directly on the alternator terminals with an independent instrument In case of inverter failure or oil pressure oil temperature or exhaust temperature limit exceeding the error will be indicated on the PMG local panel bottom left refer to Figure 7 6 2 1 PROBLEM Troubleshooting table for alternator CAUSE No output voltage at all e Low engine RPM e Alternator failure Genverter output voltage too low e Alternator failure e Circuit breaker off or faulty fuse MAINTENANCE 6 2 Alternator electrical faults Beware of parts which are live The alternator generates voltage up to 650 V Remove 3 A fuse from the control panel while working on the Genverter in order to prevent the engine from starting SOLUTION Check switches and fuses and measure directly on the alternator to exclude exte
24. 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 soot WARNING 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 OPERATION thermal load to the engine Furthermore do not stop the engine with the decompression lever unless in emergency when there is total loss of control Act as follows 1 Prior to switching off the WP GV4 Piccolo decrease the load i e turn off most electrical users and let the Piccolo run at low load for approx 5 minutes to allow the engine to get properly cool the influent coolant oil must flow through the system in order to cool the engine If the Genverter is operating in a hot environment and you do not act as given above the excessive heat in the engine can trip the high temperature 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 Genverter because of the voltage drop that occurs as the engine comes to a halt Press the STOP button and hold for 2 seconds Switch to another 230V power source if available M GV4 Piccolo June 2015 EN aw 15 MAINTENANCE 5 MAINTENANCE 5 1 Maintenance intervals ENE CN ap bef
25. ncludes a fan that circulates air to cool the windings Further technical data on the design of the alternator can be found in drawings and diagrams in this manual 3 1 3 Control WP PMG POWER MODULE GENVERTER Through the WP PMG Power Module Genverter the user can control and operate the GV4 Piccolo TECHNICAL INFORMATION REMOTE CONTROL PANEL applicable for the DDC control box configuration The DDC box remote control panel displays various process parameters and it allows the user to realize operational settings Sat Select ed ST gt whisper Frontier Ne n a ET A WHEPER GENERATOR CONTROL 1 Start button 2 Stop button 3 Select button 4 Set button 5 Failure lamp 6 Generator load indicator 7 Display Figure 2 Digital diesel remote control panel 3 1 4 Power Module As far as PMG operation and functionality is concerned the Genverter reader is referred to the PMG User s Manual 3 1 6 Battery charger The WP Piccolo system includes a battery charger generating 7A 13 7VDC to charge the starter battery 3 1 7 Load indicators Refer to Figure 3 both the PMG local panel and the remote control indicate the AC load Also the optional external DDC control box if applicable displays the load Figure 3 Remote and DDC box load indication 3 1 8 Fuel SPECIFICATIONS The engine must only be used with diesel fuel oil which conforms to the standards fo
26. oder a eines 6 3 TECHNICAL INFORMA 31 Parts and relevant 3 1 1 3 1 2 3 1 3 3 1 4 3 1 6 3 1 7 3 1 8 3 1 9 BCN E ON AEN 8 3 1 10 Oilcooline heat exchanger isaac a E E E ta 9 3 2 Re nae ee EIEEEI ET AA ao EN EIE E TE E EAE E ee De E eo AES E 10 3 2 1 E Ue E E E E a E te 10 3 2 2 PPS Se TEA IONS aa ar ao ie ado nn 12 3 2 3 L bricating oil specification S RE RS eases 12 3 2 4 Electrica AS O ETA T A EAE EAR 12 4 OPERATION ae ne e eaa 13 4 1 General sisxcvssasvaceshesasiwonssdecanaedvandsneonacnsdernsqwandacneessns vanes venoeensnaeaasesndbdssesenteeeds ddaswsesslansnninndieesaswetsaussbaeseswsvebesitonsiseeaiessvmnesnsoenns 13 4 2 VDS SPES HNN ae derven tec pares ET EA AEA EA AEA EEEE AEA 13 4 3 SPV MNP ee UCT ONG SR den be ere ns tated vase ee a mt a et a Loan one 13 4 3 1 Summarized operating instructions daily use seins 13 4 3 2 Extended operating Instructions isc idssssssinnsiversanndsacendsvncsedesabascanaapeddanndaacenseeutedsbeavetddausboacaasdedeenvastesadasedascoambuesss 14 5 MAINTENANCE weicasesccicatetratincctsnsdectancsaeccosaeereocasatcauacytateeasetenesneetansneeudnssanenbasweuenbssanenaesvaausdsnsesneancuasesdersancsaeuebseeeueousaatenraesseeniaee 16 5 1 Tea Cy ANN I CONV lI ES SR Re EE 16 5 2 PRM IAI hip nn 16 Do E T e E a te de astern ee a de aie 16 5 3 1 Preliminary INSTFUCTIONS s0ccccscssscccsssscecscsssseccususcecscsssseseeeusscesseusssccncussssenssssssencassesceesessensessssensusescesscesses 16 5 3 2 Bl Tae O aa E
27. on eng Refer to the maintenance chapter Ch 5 for details LUBRICATING OIL PRESSURE e Minimum at idle 49 kPa 0 5 kgf cm 7psi e Normal at 3000 rpm 147 490 kPa 1 5 5 kgf cm 21 71 psi e Minimum at 3000 rpm 98 kPa 1 0 kgf cm 14 psi M GV4 Piccolo June 2015 EN en it is not possible to drain the oil from the heat exchanger every time the oillis changed o oil from the engine sump as we should pump out the engine s possible and increase the oil change frequency to once every 100 running hours A dedicated interval recommendation can be provided for special applications by WhisperPower TECHNICAL INFORMATION 3 2 Technical data 3 2 1 General GENERAL SPECIFICATIONS Intermittent power Continuous power ambient temperature Peak power 5 seconds RPM range Nominal output voltage frequency Nominal output current Voltage tolerance Frequency tolerance MECHANICAL DIMENSIONS AND WEIGHT Genverter h x w xd Genverter dry weight WP PMG h x w x d WP PMG dry weight WP GVC remote panel h x w x d WP GVC remote panel weight Temperature range operational Temperature range storage Protection degree Max operating angle Relative humidity Material color Service interval ENGINE SPECIFICATIONS Engine brand Engine model Intermittent power Continuous power Number of cylinders Operation principle Displacement Bore amp stroke Air intake system Combustion air con
28. or leaks 6 Check all cables and terminal connections CHECKS DURING LONGER OPERATION Check engine load during longer operation The first 50 hours of running the continuous load should be restricted to 70 of maximum load Running for long periods at no load or light load in the first 50 hours can cause cylinder glazing and high oil consumption 1 Ensure that the WP GV4 Piccolo is not overloaded Overloading occurs when the electrical load demand is so high that the alternator 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 Genverter should therefore only be loaded at the maximum rated power for short periods 2 3 hours only M GV4 Piccolo June 2015 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 froma still stand state In order to prolong the Genverter life expectancy the nominal electrical demand on the system should be about 70 or the rated Genverter s maximum load Please note this when switching on your electrical devices Nevertheless the M GV4 Piccolo is designed so as not to overheat even under extreme conditions Do not run the Genverter for very long periods at no load or at very low load When this is necessary do load the Genverter at
29. ore after every every every every each 35 50h 200 h 400 h 800 h 1600 h start 6M 12M 24M Lubricatingoil check oil level change oil and oil filter cartridge 12M check lubricating oil pressure Coolingsystem check and clean radiator if installed replace water pump impeller a i a i o fi a EE RE fear un PT Pieter een a Fuel system RE a NE o check injection nozzles and injection pressure O check injection pump Air supply check air strainer and filter element Cylinder head inde ma pe DEHN B necessary to prime the fuel system Push the start button 5 2 Alternator activating the electric system and activating the fuel pump The alternator does not require any maintenance When more time is needed to bleed push start and hold the button on the local control panel so not on the remote 5 3 Engine panel When holding the button the pump will work but the 5 3 1 Preliminary instructions unit will not start Hold as long as necessary to bleed the All regular maintenance can be carried out when the enclosure system is open When oil and dirt has gathered in the enclosure 5 3 3 Vie Da measures have to be taken to avoid spilling oil and polluting the When theangneis incold condition both valves tan environment outlet should have a clearance of 0 15 0 03mm The first service on the engine should be carried out after 50 Rn 5 3 4 Replacing fuel filter h
30. ormity for more details 2 INFORMATION 2 1 Safety 2 1 1 Warnings and symbols Safety instructions and warnings are marked in this manual by the following pictograms indicating that a piece of equipment routine circumstance procedure etc deserves extra attention WARNING This 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 M GV4 Piccolo June 2015 EN WARNING Moving machinery his symbol indicates that a potential hazard exists caused by moving parts and draws attention to special warnings instructions or procedures which if not strictly observed may result in severe personal injury or loss of life This danger symbol refers to toxic danger caused by Carbon monoxide CO and draws attention to special warnings instructions or procedures which if not strictly observed may result in severe personal injury or loss of life 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 2 1 2 General INFORMATION If the W GV4 Piccolo is switched off during maintenance and or repair activities it should be secured against unexpected and unintentional switching on e
31. ours of its life and after a major overhaul In the first 50 hours Filter change is needed when the fuel is contaminated and as the engine should receive special attention part of preventive maintenance at least every 400 running e Long periods of light or no load running in the first 50 hours Before changing the filter clamp off the supply line hours may lead to cylinder glazing and high oil Remove the hoses from filter and attach them on the new filter consumption again The arrow on the filter housing indicates the direction of o the flow A clogged filter results in a lack of output of the e For the same reason it is of the greatest importance a engine and irregular running to use the right oil specification a 5 3 5 Cleaning oil strainer e The first time starting up or after running out of fuel it an a The oil strainer is in front of the service side Cleaning has to be could be necessary to prime the fuel system executed according to the maintenance schedule refer to 5 3 2 Bleeding fuel lines section 5 3 1 and Chapter 7 Drain the oil using a vacuum Ensure there is sufficient fuel The system is self bleeding The pump put some tissues under the cap first time starting up or after running out of fuel it could be 16 M GV4 Piccolo June 2015 EN 5 3 6 Air filter element The W GV4 Piccolo is standard supplied with an air inlet filter element Filter change depends on
32. ower Servicefirma nur f r mit L markierten Servicearbeiten Cachet et adresse compl te du centre de services WhisperPower seulement pour les travaux marqu s L Inspection required at Vorgesehen bei Inspection exig e apr s Service level Inspektionskategorie Cat gorie d inspection Hours on indicator Stand Betriebsstundenz hler Etat du compteur d heures O O O N HR O S A A EE I a a T C e a S I a Pe a a a T M GV4 Piccolo June 2015 EN 25 MAINTENANCE Inspected by Seal stamp amp full address of responsible WhisperPower Priifer Service Center only applicable to items marked LI Contr leur Stempel bzw volle Adresse der Whisperpower Servicefirma nur f r mit L markierten Servicearbeiten Cachet et adresse compl te du centre de services WhisperPower seulement pour les travaux marqu s H Inspection exig e apr s Cat gorie d inspection Stand Betriebsstundenz hler Etat du compteur d heures 5 D D D D B O Q Q 74 Vorgesehen bei Service level Inspektionskategorie Hours on indicator 4400 h 4600 h 4800 h 1 2 3 4 pe f ef q sjen aac 8800 h 9000 h 6 M GV4 Piccolo June 2015 EN PEEP ra PECECECPPEre re DOI N Supplier s Declaration of Conformity Incorporation In accordance with EN ISO 17050 1 2004 WhisperPower Genverter models M
33. place if necessary Adjust minimal RPM setting Readjust valve clearance Increase load and have the engine run for a few hours Bypassing a switch can help to confirm the failure But be aware running with a by passed alarm switch can cause damage Replace the switch By passing the switch makes it possible to keep running But be aware running with a by passed alarm switch can cause damage 21 ill TROUBLESHOOTING PROBLEM Engine stops by itself CAUSE e Overload or short circuit SOLUTION Switch off the consumers and test for short circuit e Cooling water temperature too high e Lack of fuel e Oil pressure low oil pressure switch tripped e Air or water in the fuel e Blocked air or fuel filter e Loss of compression by wear out or If necessary contact WhisperPower service department for advice Check raw water pump refer to section 6 2 3 Replace impeller and or gasket if necessary Check fuel supply system tank level fuel lines pump filter valves etc and take appropriate action Check oil level Refill if necessary Check oil pressure and have engine repaired by WhisperPower if necessary Check and clean Repair by WhisperPower service damage Loss of power e Wrong measurement Check if the load is measured correctly Does the Amp meter show the correct value When calculating the load by multiplying voltage and amps this should be done using the exa
34. pressure complete 40401240 n Fuetpumpsolenoid O Vooo 40401386 D Starter motor 1 JG 40201270 Raw waterpump complete refek to section 6 2 3 40209011 Kit ME 50209013 gasket 50209012 refer to section 6 2 3 40201029 Cover type K 50209018 Cover bolts 6PC 50201251 Pump repair kit A consisting of Shaft 50201011 Bearings 2 pcs 50209014 O ring 50209017 Seals 2 pcs 50209015 Clips 1 set 2x 50209019 1x 50209016 50209010 Pump repair kit B same as repair kit A except for the shaft 40401029 Oil cooler and all fittings 40401018 Oil pipes and fittings 40401024 Water hoses and clamps 40401031 Fuel hose kit More extensive parts list on the internet WWW WHISPERPOWER COM fast moving parts M GV4 Piccolo June 2015 EN MAINTENANCE 8 MAINTENANCE LOG Maintenance log Wartungslogbuch Journal de maintenance This log mustremain with the generator In the Dieses Logbuch verbleibt an Bord Im Falle eines Ce journal demeure a bord En cas de pr tention event of a warranty claim a copy of thisloghasto Garantieanspruchs muss eine Kopie an den a garantie une copie est a dresser au fabricant be sent to the manufacturer Hersteller geschickt werden Inspected by Seal stamp amp full address of responsible WhisperPower Priifer Service Center only applicable to items marked LJ Contr leur Stempel bzw volle Adresse der Whisperp
35. r use in modern diesel engines Fuel free from water and contaminants is of the utmost importance Detailed fuel specifications are listed in section 3 2 2 BIO DIESEL of Fatty Acid Methyl Esters FAME known on the market as 5B as thes B5 diesel fuels meet the suppers or DIESEL PREHEATER As an option a diesel pre heater can be mounted This is a special feature for applications in extreme cold conditions In this case the fuel filter will be inside the canopy and before the filter will be a heating element that will prevent the formation of paraffin crystals in the diesel and clogged filters as a result The operation is temperature related The system is controlled by an independent switch to turn it on or off 3 1 9 Lubricating oil SPECIFICATIONS The engine must be run on heavy duty lubricating oil meeting the requirements in section 3 2 3 A well known brand is recommended It is very important to use the correct oil specification Very often local oil suppliers recommend a higher API class because they assume that a higher class is allowed This is not the case One should not follow these recommendations as these higher class oils contain additives that could cause high oil consumption Never mix different types of oil M GV4 Piccolo June 2015 EN OIL VISCOSITY We recommend multi grade oil 15W40 Cold or hot conditions a special grade could be applied according to the Viscosity Chart b
36. rnal causes Check the engine RPM and adjust Contact WhisperPower Service Contact WhisperPower Service when in no load condition and RPN is above 2500 RPM en Genverter output voltage too low erloaded when under load but OK in no load sufficient engina RP condition e Engine RPM drops when loaded 6 3 Engine faults Remove 3 A fuse from the control panel while working on the Genverter in order to prevent the engine from starting 6 3 1 General When the engine is not cranking well starting problems almost always originate from battery problems or poor battery cable connections 6 3 2 PROBLEM Troubleshooting table for engine CAUSE Diesel engine fails to crank no response at all e Battery switch off e Batter completely empty M GV4 Piccolo June 2015 EN e Faulty fuse on the control panel TN Switch off a load reduce number of consumers um RPM setting Refer to Engine speed drops section in 6 2 When the engine does crank starting problems almost always originate from lack of fuel or air bubbles in the fuel pipes A failure code is displayed when a hardware failure at the engine is detected SOLUTION Replace fuse Switch on Charge or replace battery 19 TROUBLESHOOTING PROBLEM Diesel engine fails to crank the starter makes clicking noises or the engine cranks very slowly Starter is turning engine smoothly but engine fails to st
37. shield is closed is very safe when the sound Nevertheless take note of the signs on the Genverter which show symbols in a triangle indicating danger e The Genverter should be operated by authorized personnel only e Be aware of hot parts and especially parts of the exhaust system and the cooling system Do not use the M GV4 Piccolo inside a boat house or in other enclosed areas e Ifthe Genverter is unsafe fit danger notices and disconnect the battery positive lead so that it cannot be started until the condition is corrected e Do not attempt to operate the Genverter with a known unsafe condition Disconnect the battery positive lead prior to attempting any repairs or cleaning inside the enclosure e Always consult the manual before carrying out maintenance e Do not change the settings without consulting the manufacturer Keep a record of setting changes in this manual INFORMATION 2 1 9 Fire and explosion Fuels can be flammable Proper handling limits the risk of fire and explosion WARNING Never use the W GV4 Piccolo in situations where there is danger of gas or dust explosion or potentially flammable products e Avoid refilling the fuel tank while the engine is running When oil or fuel is leaking do not use the GV4 Piccolo e 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
38. sumption Fuel Fuel consumption Fuel temperature Fuel lift pump engine Electrical pump 12VDC external Oil capacity Oil exchange Service interval oil change Engine cooling Nominal control voltage Nominal starter battery requirement Battery charger function Protections 10 Article no 49002005 ar Muuhispzer ki 4 Power i 5 al M GV 4 Piccolo Genverter Marine Programmable rpm variable speed single phase Genverter 1 cyl 230V 3 8kVA 50Hz PM Technology 4 4KVA 4 0kW at 3600rpm 4 4kVA 3 5kW at 3000rpm 8kVA surge 200 2800 3600rpm programmable rpm 230V 50Hz 20 5A 5 0 1 520 x 450 x 461mm 68 8kg incl polyester sound shield 420 x 196 x 148mm 7 2kg 55 x 144 x 22mm table top flush mounting 0 4kg 10 C 40 C derating to zero at 65 C P24 gnic compartment IP21 mia me z 257jn all directions S Wax 95 RH non condensing RP sound shield RAL 9010 white black metallic 150h WhisperPower WP1 4 8kW 6 4hp rated at 3600rpm SAE J1349 ISO 3046 1 4 3kW 5 8hp rated at 3000rpm 1 Energize to run 0 306 liter 78 x 76mm Naturally aspired 0 42 m3 min Fuel 0 8 1 2 liter h Fuel temperature Max 40 C at fuel injection pump Electrical pump 12VDC external standard included 2 liter External suction pump not included 200 hours Indirect oil cooling to sea water by heat exchange Electrical 12VDC common ground
39. t switching off e Loss of control py lubricatipe linder rings c TROUBLESHOOTING SOLUTION Reduce the electrical load switch off some consumers Check fuel supply and clean fuel filter Drain oil to proper level Check air intake clean air filter Check the exhaust piping If necessary contact WhisperPower service department for advice Contact WhisperPower service department for advice Genverter must be sent to manufacturer for repair of damaged bearing or winding Repair by WhisperPower service Faulty Digital Diesel Control unit Stop the engine manually using the stop handle Check wire connections to stop solenoid Check solenoid valve function Replace if necessary Check th oildeve Check the compression If necessary Contact WhisperPower service department for advice e When the engine RPM is ramping up to react at a load step some smoke may be unavoidable e Wrong setting of minimum RPM e Sooty black smoke incomplete combustion caused by overload choked air filter air inlet temperature too high unsuitable fuel or water in fuel e Valve clearance incorrect e Continuous running with very low load e Protection system stops the engine this can be caused by oil pressure failure loose wire or faulty alarm switch e Faulty alarm switch sensor No action required Readjust minimum rpm setting Check the fuel Check for overload Check the air filter Re
40. tions EN 61000 6 2 immunity EN 60950 1 EN 609335 1 EN 60335 2 29 safety EN 68 2 6 vibration EN 6094 maritime navigation and radiocommunication UL 458 power converters inverters SYSTEM ACCESSORIES Base plate optional Aluminium mounting plate 600 x 400mm Wet exhaust hose 40mm 1 Water lock 40mm 1 Water gas separator 40mm 1 Fuel filter water separator 30micron Fuel inlet and return 8mm tube Inlet valve sea water scoop 3 4 inlet 12 5mm out Water strainer in out Water strainer in out 12 5mm Siphoning valve Siphoning valve 12 5mm Seawater inlet suction hose Seawater inlet suction hose 12 5mm Underwater inlet filter 12 5mm Starter battery AGM 12V 55Ah AGM 12V 55Ah Starter kit Starter kit Inverter charger WP Combi WP Supreme Combi Battery charger WP Supreme battery charger Service batteries AGM GEL M GV4 Piccolo June 2015 EN 11 TECHNICAL INFORMATION 3 2 2 Fuel specifications Diesel Fuel Specification EN590 96 European Union Bio diesel EN 14214 No 2 R No 1 D ASTM D975 94 Bio diesel ASTM D 6751 3 2 3 Lubricating oil specifications The engine must be run on heavy duty lubricating oil meeting the requirements of API class CH 4 Cl 4 or CJ 4 It is recommended to use a well known brand 3 2 4 Electrical diagrams Refer to the WP GV4 Piccolo Installation Manual for system drawings presenting connections
41. tions FIRST TIME CHECKS Check when starting the first time or after a longer period of rest orange oil screw plug on the cylinder head cover has to be removed Add 2ml of engine lubrication oil before starting Push down the decompression lever It will return automatically when cranking Never use ether or gasoline for cold start as it could damage the engine Warm up the engine without load for 3 minutes 3 Arestart protection prevents starting the engine when it is already running which may cause damage CHECKS WHILE IN OPERATION When in operation perform the following operational checks on a regular basis 1 Check for abnormal noise or vibration 2 Check the output parameters on the remote control display 3 Switch the power source selector switch to Power Source Genverter Before loading the Genverter up to maximum have it run warm Make sure that continuous load does not exceed 70 of maximum load also refer to CHECKS DURING LONGER OPERATION This is indicated on the top left part of the PMG local panel Figure 7 14 Check for any damages caused by transport or installation Check ifthe installation conforms to the installation instructions O J 3 Ensure the engine is free to turn without obstruction 4 By using the decompression handle one can crank the engine easily with a screwdriver clockwise pushing the starter gear 5 Check all hoses and hose connections f
42. to be done at top dead centre TDC of the compression stroke Using a pocket light one can check the position of the flywheel alternator refer to Figure 9 for visualization reasons the PM cover was temporarily removed When one cannot see t TDC can be found by rote valve to open and close Rotating the flywheel can be realized by means of the flywheel turning tool article number 98002002 also refer to Figure 10 18 a gt Figure 10 Turning tool to move to Top Dead Center position To be able to access the turning tool insertion point first disassemble the water pump Rotate the flywheel clockwise allowing the exhaust valve to open and close and the intake valve to open and close After the intake valve has closed rotate the flywheel clockwise an additional turn At this position the piston will be on compression stroke and both valves will be closed allowing valve clearance adjustment to be completed Before closing the valve cover apply some oil to the contact surface between the adjusting screw and push rod Use a new valve cover gasket 5 5 Putting out of service When not using the Genverter for a longer period it is recommended to execute an engine preservation procedure 1 Clean the engine 2 Loosen the fuel suction pipe and fuel return and put them in a can with preservation diesel fuel Start the engine and run the engine warm Stop the engine Drain the hot efill w
43. tron E E E AEA EAEE aaar a i n 19 6 2 1 Troubleshooting table for alternator sise 19 6 3 Engine faults iecaecavataewairsnnsnsdsvedaanstnurhednuss oitamarsuaceades elunpdssensn rudaothcwwentoncnadssicdeusisdunsneuieastensieacasnabesncuresirsansueseradeneotancsoscintncweanianieen 19 6 3 1 E eh a eten edt is beeen 19 6 3 2 Troubleshooting table for NBNe csiscereccrcsscecprdeecacerseseseaseccsacnotetaprinaneaseialantian ater iene iia 19 6 4 RAN WASE PUM EEE 23 6 5 LUE LEO nt oS EEE 23 6 6 UIC OO aa ea don na ant se 6 don ananas ei de I a ct A 23 7 SPARE PARTS LIST cinner teens 24 8 MAINTENANCE LOG eines keers annn soms nes oes sente peter nantes ind ea nen enden endnenan ende ATEA ween enen 25 EC Declaration of Conformity aw M GV4 Piccolo June 2015 EN 3 INFORMATION 1 INTRODUCTION 1 1 General This manual serves as a guideline for the safe and effective operation maintenance and possible correction of minor malfunctions of the M GV4 Piccolo manufactured and marketed by WhisperPower It is therefore obligatory that every person who works on or with the W GV4 Piccolo must be completely familiar with the contents of this manual and that he she carefully follows the instructions contained herein 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
44. ured 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 Genverter avoid any risk of personal injuries do not stand under the Genverter e Use soft slings to avoid damage e Onthe engine is a lifting hoist eye which can be used to take the Genverter out of the capsule It can also be used to lift the complete Genverter including the capsule e After transporting the Genverter check for damage before installation e 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 ing on the engine speedxThe separate power module will invert this output to 230V 5 2 3 3 Control Digital Diesel Control incorporated in the Power Module Genverter is based on microprocessor technology DDC takes care of engine operation monitoring and control refer to Digital Diesel Control user s manual for DDC specifications and possibilities The full automatic remote control panel including 10 meter cable comes as standard with the Genverter 2 3 5 Documentation Included in the delivery are e This user s manual number 40200821 e
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