Multiquip Portable Generator DA7000SS User Manual

OPERATION AND PARTS MANUAL  
MODELS  
DA7000SS-DA7000SSA  
DA700SSW-DA7000WGH  
PORTABLE GENERATORS  
(KUBOTA Z482 SERIES DIESEL ENGINES)  
Revision #5 (01/20/11)  
To find the latest revision of this  
publication, visit our website at:  
www.multiquip.com  
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.  
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PROPOSITION 65 WARNING  
Diesel engine exhaust and some of  
PAGE 2 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)  
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REPORTING SAFETY DEFECTS  
If you believe that your vehicle has a defect that could cause a crash or could cause  
injury or death, you should immediately inform the National Highway Traffic Safety  
Administration (NHTSA) in addition to notifying Multiquip at 1-800-421-1244.  
If NHTSA receives similar complaints, it may open an investigation, and if it finds  
that a safety defect exists in a group of vehicles, it may order a recall and remedy  
campaign. However, NHTSA cannot become involved in individual problems  
between you, your dealer, or Multiquip.  
To contact NHTSA, you may either call the Vehicle Safety Hotline toll-free at 1-888-  
327-4236 (TTY: 1-800-424-9153), go to http://www.nhtsa.dot.gov; or write to:  
Administrator  
NHTSA  
1200 New Jersey Avenue S.E.  
Washington, DC 20590  
You can also obtain information about motor vehicle safety from  
http://www.safecar.gov.  
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 3  
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TABLE OF CONTENTS  
KUBOTA Z482-EB/E2B/E3B Die-  
sel Engines  
DA7000 SERIES GENERATOR  
Proposition 65 Warning .................................................. 2  
Reporting Safety Defects................................................ 3  
Table Of Contents........................................................... 4  
Parts Ordering Procedures............................................. 5  
Safety Information ..................................................... 6-11  
Specifications (Generator)............................................ 12  
Specifications (Engine)................................................. 13  
Dimensions................................................................... 14  
Installation ............................................................... 16-17  
General Information...................................................... 18  
Components (Generator)......................................... 19-20  
Components (Engine)................................................... 21  
Load Applications ......................................................... 22  
Inspection/Setup...................................................... 23-27  
Operation................................................................. 28-30  
Shutdown...................................................................... 30  
Preparation For Long Term Storage ............................. 31  
Maintenance............................................................ 32-35  
Maintenance (Trailer)............................................... 36-37  
Trailer Guidelines..................................................... 38-51  
Trailer Wiring Digram ................................................... 52  
Generator Wiring Digram ............................................. 53  
Engine Wiring Digram .................................................. 54  
Troubleshooting (Engine and Generator) ................ 55-56  
Troubleshooting (Engine)......................................... 57-58  
Explanation Of Code In Remarks Column.................... 60  
Suggested Spare Parts ................................................ 61  
Crankcase Assembly .............................................. 88-89  
Oil Pump Assembly ................................................ 90-91  
Oil Pan Assembly ................................................... 92-93  
Cylinder Head Assembly ........................................ 94-95  
Gear Case Assembly .............................................. 96-97  
Head Cover Assembly .......................................... 98-101  
Oil Filter Assembly .............................................. 102-103  
Dipstick and Guide Assembly ............................. 104-105  
Main Bearing Case Assembly ............................ 106-107  
Camshaft and Idle Gear Assembly ..................... 108-109  
Piston and Crankshaft Assembly ....................... 110-111  
Flywheel Assembly ............................................ 112-113  
Fuel Camshaft and Gov. Shaft Assembly ......... 114-115  
Engine Stop Lever Assembly ............................. 116-117  
Stop Solenoid Assembly ................................... 118-119  
Injection Pump Assembly ................................. 120-121  
Injection Pump Components Assembly ........... 122-123  
Speed Control Plate Assembly............................ 124-125  
Nozzle Holder And Glow Assembly..................... 126-127  
Nozzle Holder Assembly ................................... 128-129  
Fork Lever Assembly .......................................... 130-131  
Fuel Filter Assembly ........................................... 132-133  
Fuel Pump Assembly .......................................... 134-135  
Dynamo and Pulley Assembly ........................... 136-137  
Dynamo Assembly .............................................. 138-139  
Starter Assembly ................................................ 140-141  
Starter Components Assembly .......................... 142-143  
Oil Switch Assembly ........................................... 144-145  
Water Flange and Thermostat Assembly ........... 146-147  
Water Pump Assembly ....................................... 148-149  
Water Pipe Assembly ......................................... 150-151  
Fan Assembly ..................................................... 152-153  
Valve and Rocker Arm Assembly ....................... 154-155  
Inlet Manifold Assembly ...................................... 156-157  
Exhaust Manifold Assembly ................................ 158-159  
Glow Plug/Lamp and Timer Assembly .............. 160-161  
Starter Switch Assembly ..................................162-163  
Air Cleaner Assembly ....................................... 164-165  
Accessories......................................................... 166-167  
Piston Kit (Option) ............................................... 168-169  
Terms and Conditions Of Sale — Parts...................... 170  
Component Drawings  
Nameplate and Decals Assembly............................ 62-63  
Generator Assembly................................................ 64-65  
Control Panel Assembly .......................................... 66-67  
Electric Parts Assembly........................................... 68-69  
Engine And Radiator Assembly............................... 70-73  
Battery Assembly..................................................... 74-75  
Muffler Assembly..................................................... 76-77  
Fuel Tank Assembly................................................. 78-79  
Oil Filter Retrofit Assembly...................................... 80-81  
Enclosure Assembly................................................ 82-85  
Rubber Seals Assembly .......................................... 86-87  
NOTICE  
Specifications and part numbers are subject to change  
without notice.  
PAGE 4 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)  
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PARTS ORDERING PROCEDURES  
Ordering parts has never been easier!  
Choose from three easy options:  
Effective:  
January 1st, 2006  
Best Deal!  
Order via Internet (Dealers Only):  
Order parts on-line using Multiquip’s SmartEquip website!  
If you have an MQ Account, to obtain a Username  
and Password, E-mail us at: parts@multiquip.  
com.  
View Parts Diagrams  
Order Parts  
Print Specification Information  
To obtain an MQ Account, contact your  
District Sales Manager for more information.  
Use the internet and qualify for a 5% Discount  
on Standard orders for all orders which include  
complete part numbers.*  
Goto www.multiquip.com and click on  
to log in and save!  
Order Parts  
Note: Discounts Are Subject To Change  
Fax your order in and qualify for a 2% Discount  
on Standard orders for all orders which include  
complete part numbers.*  
Order via Fax (Dealers Only):  
All customers are welcome to order parts via Fax.  
Domestic (US) Customers dial:  
1-800-6-PARTS-7 (800-672-7877)  
Note: Discounts Are Subject To Change  
Domestic (US) Dealers Call:  
Order via Phone:  
1-800-427-1244  
Non-Dealer Customers:  
International Customers should contact  
their local Multiquip Representatives for  
Parts Ordering information.  
Contact your local Multiquip Dealer for  
parts or call 800-427-1244 for help in  
locating a dealer near you.  
When ordering parts, please supply:  
Dealer Account Number  
Specify Preferred Method of Shipment:  
Dealer Name and Address  
UPS/Fed Ex  
DHL  
Truck  
Priority One  
Ground  
Shipping Address (if different than billing address)  
Return Fax Number  
Next Day  
Second/Third Day  
Applicable Model Number  
Quantity, Part Number and Description of Each Part  
NOTICE  
All orders are treated as Standard Orders and will  
ship the same day if received prior to 3PM PST.  
WE ACCEPT ALL MAJOR CREDIT CARDS!  
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 5  
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SAFETY INFORMATION  
Do not operate or service the equipment before reading the  
entire manual. Safety precautions should be followed at all  
times when operating this equipment. Failure to read and  
understand the safety messages and operating instructions  
could result in injury to yourself and others.  
Potential hazards associated with the operation of this  
equipment will be referenced with hazard symbols which  
may appear throughout this manual in conjunction with  
safety messages.  
SAFETY MESSAGES  
The four safety messages shown below will inform you  
about potential hazards that could injure you or others.The  
safety messages specifically address the level of exposure  
to the operator and are preceded by one of four words:  
DANGER, WARNING, CAUTION or NOTICE.  
SAFETY SYMBOLS  
DANGER  
Indicates a hazardous situation which, if not avoided,  
WILL result in DEATH or SERIOUS INJURY.  
WARNING  
Indicates a hazardous situation which, if not avoided,  
COULD result in DEATH or SERIOUS INJURY.  
CAUTION  
Indicates a hazardous situation which, if not avoided,  
COULD result in MINOR or MODERATE INJURY.  
NOTICE  
Addresses practices not related to personal injury.  
PAGE 6 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)  
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SAFETY INFORMATION  
NEVER use accessories or attachments that are not  
recommended by MQ Power for this equipment.Damage  
to the equipment and/or injury to user may result.  
GENERAL SAFETY  
CAUTION  
NEVER operate this equipment without proper protective  
clothing, shatterproof glasses, respiratory protection,  
hearing protection, steel-toed boots and other protective  
devices required by the job or city and state regulations.  
ALWAYS know the location of the nearest  
fire extinguisher.  
ALWAYS know the location of the nearest  
first aid kit.  
ALWAYS know the location of the nearest  
phone or keep a phone on the job site. Also, know the  
phone numbers of the nearest ambulance, doctor and  
fire department. This information will be invaluable in  
the case of an emergency.  
NEVER operate this equipment when not  
feeling well due to fatigue, illness or when  
under medication.  
NEVER operate this equipment under the influence of  
drugs or alcohol.  
GENERATOR SAFETY  
DANGER  
NEVER operate the equipment in an explosive  
atmosphere or near combustible materials.An  
explosion or fire could result causing severe  
bodily harm or even death.  
ALWAYS check the equipment for loosened threads or  
bolts before starting.  
DO NOT use the equipment for any purpose other than  
its intended purposes or applications.  
WARNING  
NEVER disconnect any emergency or safety devices.  
These devices are intended for operator safety.  
Disconnection of these devices can cause severe injury,  
bodily harm or even death.Disconnection of any of these  
devices will void all warranties.  
NOTICE  
This equipment should only be operated by trained and  
qualified personnel 18 years of age and older.  
Whenever necessary, replace nameplate, operation and  
safety decals when they become difficult read.  
CAUTION  
Manufacturer does not assume responsibility for any  
accident due to equipment modifications. Unauthorized  
equipment modification will void all warranties.  
NEVER lubricate components or attempt service on a  
running machine.  
NOTICE  
ALWAYS ensure generator is on level ground before use.  
ALWAYS keep the machine in proper running condition.  
Fix damage to machine and replace any broken parts  
immediately.  
ALWAYS store equipment properly when it is not being  
used.Equipment should be stored in a clean, dry location  
out of the reach of children and unauthorized personnel  
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 7  
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SAFETY INFORMATION  
ENGINE SAFETY  
DANGER  
NOTICE  
NEVER run engine without an air filter or with a dirty air  
filter.Severe engine damage may occur.Service air filter  
frequently to prevent engine malfunction.  
The engine fuel exhaust gases contain poisonous carbon  
monoxide. This gas is colorless and odorless, and can  
cause death if inhaled.  
NEVER tamper with the factory settings  
of the engine or engine governor. Damage  
to the engine or equipment can result  
if operating in speed ranges above the  
maximum allowable.  
The engine of this equipment  
requires an adequate free  
flow of cooling air. NEVER  
operate this equipment in  
any enclosed or narrow area  
where free flow of the air is  
restricted. If the air flow is  
restricted it will cause injury to people and property and  
serious damage to the equipment or engine.  
Wet stacking is a common problem with diesel engines  
which are operated for extended periods with light or  
no load applied.When a diesel engine operates without  
sufficient load (less than 40% of the rated output), it will  
not operate at its optimum temperature. This will allow  
unburned fuel to accumulate in the exhaust system,  
which can foul the fuel injectors, engine valves and  
exhaust system, including turbochargers, and reduce  
the operating performance.  
WARNING  
DO NOT place hands or fingers inside engine  
compartment when engine is running.  
In order for a diesel engine to operate at peak efficiency,  
it must be able to provide fuel and air in the proper ratio  
and at a high enough engine temperature for the engine  
to completely burn all of the fuel.  
NEVER operate the engine with heat shields or  
guards removed.  
Keep fingers, hands hair and clothing away  
from all moving parts to prevent injury.  
Wet stacking does not usually cause any permanent  
damage and can be alleviated if additional load is  
applied to relieve the condition.It can reduce the system  
performance and increase maintenance. Applying an  
increasing load over a period of time until the excess  
fuel is burned off and the system capacity is reached  
usually can repair the condition. This can take several  
hours to burn off the accumulated unburned fuel.  
DO NOT remove the radiator cap while the  
engine is hot. High pressure boiling water  
will gush out of the radiator and severely  
scald any persons in the general area of  
the generator.  
DO NOT remove the coolant drain plug while the engine  
is hot. Hot coolant will gush out of the coolant tank and  
severely scald any persons in the general area of the  
generator.  
State Health Safety Codes and Public Resources  
Codes specify that in certain locations, spark arresters  
must be used on internal combustion engines that use  
hydrocarbon fuels.A spark arrester is a device designed  
to prevent accidental discharge of sparks or flames  
from the engine exhaust. Spark arresters are qualified  
and rated by the United States Forest Service for this  
purpose. In order to comply with local laws regarding  
spark arresters, consult the engine distributor or the  
local Health and Safety Administrator.  
DO NOT remove the engine oil drain plug while the  
engine is hot. Hot oil will gush out of the oil tank and  
severely scald any persons in the general area of the  
generator.  
CAUTION  
NEVER touch the hot exhaust manifold,  
muffler or cylinder.Allow these parts to cool  
before servicing equipment.  
PAGE 8 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)  
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SAFETY INFORMATION  
Make sure the hitch and coupling of the towing vehicle  
are rated equal to, or greater than the trailer “gross  
vehicle weight rating.”  
FUEL SAFETY  
DANGER  
DO NOT start the engine near spilled fuel or combustible  
fluids. Diesel fuel is extremely flammable and its vapors  
can cause an explosion if ignited.  
ALWAYS inspect the hitch and coupling for wear. NEVER  
tow a trailer with defective hitches, couplings, chains, etc.  
Check the tire air pressure on both towing vehicle and  
trailer. Trailer tires should be inflated to 50 psi cold.  
Also check the tire tread wear on both vehicles.  
ALWAYS refuel in a well-ventilated area, away from  
sparks and open flames.  
ALWAYS use extreme caution when working with  
flammable liquids.  
ALWAYS make sure the trailer is equipped with a safety  
chain.  
DO NOT fill the fuel tank while the engine is running  
or hot.  
ALWAYS properly attach trailer’s safety chains to towing  
vehicle.  
DO NOT overfill tank, since spilled fuel could ignite if it  
comes into contact with hot engine parts or sparks from  
the ignition system.  
ALWAYS make sure the vehicle and trailer directional,  
backup, brake and trailer lights are connected and  
working properly.  
Store fuel in appropriate containers, in well-ventilated  
areas and away from sparks and flames.  
DOT Requirements include the following:  
• Connect and test electric brake operation.  
NEVER use fuel as a cleaning agent.  
• Secure portable power cables in cable tray with tie  
wraps.  
DO NOT smoke around or near the  
equipment. Fire or explosion could result  
from fuel vapors or if fuel is spilled on a  
hot engine.  
The maximum speed for highway towing is 55 MPH unless  
posted otherwise.Recommended off-road towing is not to  
exceed 15 MPH or less depending on type of terrain.  
TOWING SAFETY  
CAUTION  
Avoid sudden stops and starts.This can cause skidding,  
or jack-knifing. Smooth, gradual starts and stops will  
improve towing.  
Check with your local county or state safety  
towing regulations, in addition to meeting  
Department of Transportation (DOT)  
SafetyTowing Regulations, before towing  
your generator.  
Avoid sharp turns to prevent rolling.  
Trailer should be adjusted to a level position at all times  
when towing.  
Raise and lock trailer wheel stand in up position when  
towing.  
Refer to MQ Power trailer manual for additional safety  
information.  
Place chock blocks underneath wheel to prevent rolling  
while parked.  
In order to reduce the possibility of an accident while  
transporting the generator on public roads, ALWAYS  
make sure the trailer that supports the generator and  
the towing vehicle are mechanically sound and in good  
operating condition.  
Place support blocks underneath the trailer’s bumper  
to prevent tipping while parked.  
Use the trailer’s swivel jack to adjust the trailer height to  
a level position while parked.  
ALWAYS shutdown engine before transporting  
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 9  
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SAFETY INFORMATION  
Make sure power cables are securely connected to the  
generator’s output receptacles. Incorrect connections  
may cause electrical shock and damage to the  
generator.  
ELECTRICAL SAFETY  
DANGER  
DO NOT touch output terminals during  
operation. Contact with output terminals  
duringoperationcancauseelectrocution,  
electrical shock or burn.  
NOTICE  
ALWAYS make certain that proper power or extension  
cord has been selected for the job. See Cable Selection  
Chart in this manual.  
The electrical voltage required to  
operate the generator can cause severe  
Grounding Safety  
DANGER  
injury or even death through physical contact with live  
circuits. Turn generator and all circuit breakers OFF  
before performing maintenance on the generator or  
making contact with output terminals.  
ALWAYS make sure that electrical circuits are properly  
grounded to a suitable earth ground (ground rod) per  
the National Electrical Code (NEC) and local codes  
before operating generator. Severe injury or death by  
electrocution can result from operating an ungrounded  
generator.  
NEVER insert any objects into the output  
receptacles during operation. This is  
extremely dangerous.The possibility exists  
of electrical shock, electrocution or  
death.  
NEVER use gas piping as an electrical ground.  
Backfeed to a utility system can cause  
electrocution and/or property damage.  
NEVER connect the generator to a  
building’s electrical system without  
a transfer switch or other approved  
device. All installations should be  
performed by a licensed electrician in accordance with  
all applicable laws and electrical codes. Failure to do so  
could result in electrical shock or burn, causing serious  
injury or even death.  
Power Cord/Cable Safety  
DANGER  
NEVER let power cords or cables lay in water.  
NEVER stand in water while AC power from the  
generator is being transferred to a load.  
NEVER use damaged or worn cables or cords when  
connecting equipment to generator. Inspect for cuts in  
the insulation.  
NEVER grab or touch a live power  
cord or cable with wet hands. The  
possibility exists of electrical shock,  
electrocution or death.  
PAGE 10 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)  
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SAFETY INFORMATION  
BATTERY SAFETY  
DANGER  
ENVIRONMENTAL SAFETY  
NOTICE  
DO NOT drop the battery. There is a possibility that the  
battery will explode.  
Dispose of hazardous waste properly.  
Examples of potentially hazardous waste  
are used motor oil, fuel and fuel filters.  
DO NOT expose the battery to open flames,  
sparks, cigarettes, etc.The battery contains  
combustible gases and liquids. If these  
gases and liquids come into contact with a  
flame or spark, an explosion could occur.  
DO NOT use food or plastic containers to  
dispose of hazardous waste.  
DO NOT pour waste, oil or fuel directly onto the ground,  
down a drain or into any water source.  
WARNING  
ALWAYSwearsafetyglasseswhenhandling  
the battery to avoid eye irritation.The battery  
contains acids that can cause injury to the  
eyes and skin.  
Use well-insulated gloves when picking up the battery.  
ALWAYS keep the battery charged. If the battery is not  
charged, combustible gas will build up.  
ALWAYS recharge the battery in a well-ventilated  
environmenttoavoidtheriskofadangerousconcentration  
of combustible gasses.  
If the battery liquid (dilute sulfuric acid) comes into  
contact with clothing or skin, rinse skin or clothing  
immediately with plenty of water.  
If the battery liquid (dilute sulfuric acid) comes into  
contact with eyes, rinse eyes immediately with plenty  
of water and contact the nearest doctor or hospital to  
seek medical attention.  
CAUTION  
ALWAYS disconnect the NEGATIVE battery terminal  
before performing service on the generator.  
ALWAYS keep battery cables in good working condition.  
Repair or replace all worn cables.  
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 11  
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SPECIFICATIONS (GENERATOR)  
Table 1. Specifications (Generator)  
DA7000SS/DA7000SSA  
DA7000SSW/DA7000SSWGH  
Model  
Type  
2-Pole Brushless Revolving Field Type  
Excitation  
Solid State, Statically Excited System  
Speed  
3,600 RPM  
Self-Ventilation  
7 kW  
Cooling System  
Max Power Output  
Continuous Power Output  
Rated Voltage  
AC Generator  
60 Hz AC Power Source  
6 kW  
120/240V  
Current Max/Continuous (120V)  
Current Max/Continuous (240V)  
Phase  
58.3/50 amps  
29.2/25 amps  
Single Phase (4 wire)  
60 Hz  
Frequency  
Power Factor  
1
Battery  
12V -35Ah  
Dimensions  
(L x W x H)  
25.6 x 44.9 X 31.3 in.  
(650 X 1,140 X 795 mm)  
Dry Net Weight  
526 lbs. (239 kg)  
NOTICE  
In keeping with Multiquip's policy of constantly  
improving its products, the specifications quoted herein  
are subject to change without prior notice.  
PAGE 12 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)  
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SPECIFICATIONS (ENGINE)  
Table 2. Specifications (Engine)  
Kubota Engine Model  
Z482-EB Z482-E2B-DGDE-2 Z482-E3B-DGDE-2  
Tier  
1
2
4
Gen. Enclosure Color  
Type  
Orange  
Orange/White  
White  
Vertical, water-cooled, 4-cycle diesel engine  
2.64 in. X 2.68 in.  
(67 mm x 68 mm.)  
Bore X Stroke  
Displacement  
Number of Cylinders  
Max Output  
29.23 cu.-in. (479 cm3)  
2
12.5~13.9 H.P./3600 R.P.M.  
#2 Diesel Fuel  
Engine  
Fuel  
Fuel Capacity  
Fuel Consumption  
Coolant Capacity  
Lube Oil Capacity  
Oil Alert System  
Starting Method  
Battery  
6.6 gal. (25 liters)  
.7 gals. (2.63 liters)/hr.  
2.95 quarts (2.8 liters)  
2.64 quarts (2.5 liters)  
Yes  
Electric Start  
12 Volt @ 35 Ah  
Dimensions  
(L x W x H)  
13.82 x 15.31 X 20.47 in.  
(351 X 389 X 520 mm)  
Dry Net Weight  
117.1 lbs. (53.1 kg)  
Effects of Altitude and Heat  
The maximum output of the engines listed above are applicable to supplying electrical power for continuous service at  
ambient conditions in accordance with SAE Test cord J607. The above ambient conditions are at standard sea level, with  
a barometric reading of 29.92 inches and a temperature of 60° F (15.5° C).  
Generally, the engine's output power will decrease 3-1/2% for each 1000 feet (305 meters) of altitude above sea level, and  
1% for each 10° F (-12.2° C) above the standard temperature of 60° F (15.5° C).  
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 13  
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DIMENSIONS  
Figure 1. Dimensions  
PAGE 14 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)  
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NOTE  
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 15  
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