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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INSTALLATION
CONNECTING THE GROUND
The nut and ground terminal on the generator should always
be used to connect the generator to a suitable ground.The
ground cable should be #8 size wire minimum.
At the generator, connect the terminal of the ground cable
between the lock washer and the nut (Figure 2) and tighten
the nut fully. Connect the other end of the ground cable to
a suitable earth ground (ground rod).
DANGER
THE POSSIBILITY EXISTS OF ELECTROCUTION IF
GENERATOR/WELDER IS NOT PROPERLY GROUNDED.
ALWAYS CONNECT EARTH GROUND (GROUND
ROD) TO GENERATOR G.F.C.I. GROUND TERMINAL.
GROUND
CABLE
#8 MINIMUM
G
E
R
N
E
U
G
R
A
D
O
TO
R
N
L
U
G
G.F.C.I
GROUND
STUD
GROUND ROD
FOR EARTH
GROUND
CONNECT TO
BUILDING
GROUND
(OPTION)
FOR FURTHER GROUNDING
INSTRUCTIONS, READ MANUAL
8
FT. MINIMUM
REFERENCE
NEC 250-52(C)
D93110000
GROUND
S-
1
1
23
GENERATOR
GROUND LUG
GROUND ROD
FOR EARTH
GROUND
GROUND
CABLE
#8 MINIMUM
CONNECT TO
BUILDING
GROUND
IF REQUIRED
8 FT. MINIMUM
REFERENCE
NEC 250-52(C)
Figure 2. Generator Grounding
PAGE 16 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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INSTALLATION
OUTDOOR INSTALLATION
GENERATOR GROUNDING
If possible install the generator in a area that is free of
debris, bystanders, and overhead obstructions. Make sure
the generator is on secure level ground so that it cannot
slide or shift around.
To guard against electrical shock and possible damage to
the equipment, it is important to provide a good EARTH
ground.
Article 250 (Grounding) of the National Electrical Code
(NEC) provides guide lines for proper grounding and
specifies that the cable ground shall be connected to the
grounding system of the building as close to the point of
cable entry as practical.
The installation site must be relatively free from moisture
and dust.All electrical equipment should be protected from
excessive moisture. Failure to do will result in deterioration
of the insulation and will result in short circuits and
grounding.
NEC articles 250-64(b) and 250-66 set the following
grounding requirements:
Foreign materials such as dust, sand, lint and abrasive
materials have a tendency to cause excessive wear to
engine and alternator parts.
1. Use one of the following wire types to connect the
generator to earth ground.
WARNING
a. Copper - 8 AWG (5.3 mm2)
b. Aluminum - 6 AWG (8.4 mm2)
Pay close attention to ventilation when
operating the generator inside tunnels
and caves. The engine exhaust contains
noxious elements. Engine exhaust must
be routed to a ventilated area
2. When grounding the generator (Figure 2) connect the
ground cable between the lock washer and the nut on
the generator and tighten the nut fully. Connect the
other end of the ground cable to earth ground.
INDOOR INSTALLATION
3. NEC article 250-52(c) specifies that the earth ground rod
should be buried a minimum of 8 ft. into the ground.
Exhaust gases from gas engines are extremely poisonous.
Whenever an engine is installed indoors the exhaust
fumes must be vented to the outside. The engine should
be installed at least two feet from any outside wall. Using
an exhaust pipe which is too long or too small can cause
excessive back pressure which will cause the engine to
heat excessively and possibly burn the valves.
NOTICE
When connecting the generator to any buildings
electrical system ALWAYS consult with a licensed
electrician.
DANGER
PLACEMENT
Before connecting this generator to any building’s
electrical system, a licensed electrician must install an
isolation (transfer) switch.
The generator should always be placed on a flat level
surface when it is running.DO NOT place the generator on
slopes, the possibility exists that the generator could slide.
Serious injury or death may result without this transfer
switch.
DANGER
An electric shock is apt to happen when
vibrators are used. Pay close attention to
handling when operating vibrators and
always use rubber boots and gloves to
insulate the body from a short circuit.
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 17
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GENERAL INFORMATION
FAMILIARIZATION
Generator
Oil Pressure Warning Alarm
This unit is equipped with a protective device that detects
low oil pressure. If the lubricating oil pressure of this unit
should become abnormally low, the protective device will
automatically stop the engine. If this condition should
occur, please refer to the engine troubleshooting table in
this manual.
The Multiquip DA7000 Series generators are 6.0 kW
(continuous output), 7.0 kW (max output) A.C. generators
designed as a portable dual purpose power source for 60
Hz (single phase) lighting facilities, power tools, submersible
pumps and other industrial and construction machinery.
Idle Control Switch
Control Panel
The DA7000 series generators are provided with an
automatic idle (engine) control capability for noise
suppression and fuel cost reduction. The automatic idle
control feature automatically engages under a no-load
condition.
The control box is provided with the following:
GFCI 120 volt receptacle, 20 amp (single-phase)
120 volt receptacle, 25 amp (single-phase)
120/240 volt receptacle, 25 amp (single-phase)
120/240 volt receptacle, 25 amp (single-phase)
AC Voltmeter
With AC loads of more than 150W (such as lighting
equipment, motor-powered tools, submersible water
pumps, etc.), the engine runs at high speed.When a no load
condition is produced, the engine automatically slows down.
Main Circuit Breaker 265V @25 Amps
GFCI Circuit Breaker 120V @20 Amps
Idle Control Switch
Turn the idle control switch to the “ON” (up) position when
AC loads of more than 150W are connected. Turn the idle
control switch to the “OFF” (down) position when AC loads
of less than 100W or when a magnetic switch is used.
Starter Switch
Warning Lamp Unit
Excitation System
Hour Meter
The DA7000 series generators use a brushless exciter
to create rated output electricity. This system will use the
mechanical energy generated by the 3600 RPM engine
to spin the rotor (or armature) inside the generator (or
alternator end).
Ground Terminal
Engine Protection System
Engine protection fail safe features are provided in the event
of low oil pressure, high coolant temperature and failure of
the battery to charge. If any of the above conditions occur
while operating the generator it will cause a complete unit
shut down.
Excitation current is sourced from the battery to the
excitation windinding in the stator. Current applied to this
coil creates a magnetic field. The rotating armature is
induced with AC current.
Battery Charge Alarm
Engine
This unit is equipped with a protective device that signals
an alarm and automatically stops the engine when the
battery cannot be charged by the alternator.
The DA7000 series generators are powered by a water-
cooled, 4-cycle KUBOTA diesel engine. This engine is
designed to meet every performance requirement of the
generator. Reference Table 2, engine specifications.
Water Temperature Alarm
In keeping with Multiquip's policy of constantly improving
its products, the specifications quoted herein are subject
to change without prior notice.
This unit is equipped with an apparatus that signals
an alarm and automatically stops the engine when the
cooling water temperature becomes abnormally high.
This apparatus will not function properly if the machine
is operated with less than the proper amount of coolant.
Figure 3 and Figure 4 show the basic controls and indicators
for the DA7000 series generators.
PAGE 18 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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COMPONENTS (GENERATOR)
Figure 3. Generator Components
1. Fuel Gauge — Indicates the amount of fuel in the
fuel tank.
10. Automatic Speed Control Solenoid — Automatically
regulates engine speed.
2. Air Outlet Exhaust — Allows engine exhaust to exit
the generator into the open air. NEVER block this
opening.
11. Battery Terminals — Connect these terminals to the
battery. Always pay close attention to the polarity of
the terminals when connecting to the battery, RED
(positive), and BLACK (negative).
3. Fuel Cap — Remove this cap to add fuel. Add only
#2 Diesel Fuel. Always keep an adequate amount of
fuel in the tank. DO NOT top off. Wipe up any spilled
fuel immediately.
12. Fuel Filter — Prevents dirt and other debris from
entering the fuel system. Change fuel filter as
recommended in the maintenance section of this
manual.
4. Lifting Hook — Use this hook to lift the generator.
13. Air Inlet Vent — Allows outside air to enter the
generator. NEVER block this opening.
5. Engine Air Cleaner — Prevents dirt and other debris
from entering the fuel system. Lift locking latch on air
filter cannister to gain access to filter element.
14. Battery — Provides +12VDC power for the generator.
When replacing battery (12V 35 AH) use only
recommended type battery.
6. Overflow Bottle — Supplies coolant to the radiator
when radiator coolant level is low.Fill to indicated level
as shown on bottle.
15. Ground Terminal — Use this terminal to connect
external equipment grounds so that the GFCI
receptacle will have a ground path.
7. Engine Oil Filler Port — Remove this cap to add
engine oil.Use only recommended type oil.SeeTable 5.
16. FuelTank — Holds 6.6 gallons (25 liters) of diesel fuel.
8. Coolant Drain Plug — Remove this plug to drain
coolant from the radiator.
9. Oil Drain Plug — Remove this plug to drain oil from
the engine.
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 19
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COMPONENTS (GENERATOR)
below the rated voltage, engine problems may exist
(low/high RPM's).To prevent damage to the generator
or power tools turn the generator OFF and consult your
authorized Multiquip service dealer.
26. Hour Meter — Indicates number of hours machine
has been in use or hours engine was run.
27. Idle Control Switch —The generator is provided with
an automatic idle control device for noise suppression
and reduced fuel consumption.
The automatic idle control automatically engages under
a no-load condition. With the automatic idle control
switched “ON”, the engine revolutions will automatically
drop to about 2200 rpm (low-speed operation) within
3 seconds after the load stops. When the operation is
resumed, the engine speed is automatically increased
to about 3600 rpm (high-speed operation) as soon as
the load is connected.
Figure 4. Generator Components
17. Fuel drain Plug — Remove this plug to drain fuel
from the fuel tank.
28. Warning Lamp Display — Lights red when the
following conditions occur:
18. Frame Ground Lug — Connect a ground strap
between this lug and a ground rod.Make sure that the
ground rod is inserted deep into the ground to provide
a good earth ground. Consult with local Electrical and
Safety Codes for proper connection.
Oil Pressure Lamp — If the oil pressure drops
suddenly, the oil pressure lamp will go on, and
the generator will shut down.
Charge Lamp — The charge lamp will go
on when the battery fails to charge, and the
generator will shut down.
19. CS6369 Receptacle — Dual voltage receptacle,
provides 120/240 volts output at 25 amps.
Water Temperature Lamp — The water
temperature lamp will go on if the temperature
rises to an abnormally high level, and the
generator will shut down.
20. L-14-30R Receptacle — Dual voltage receptacle,
provides 120/240 volts output at 25 amps.
21. L5-30R Receptacle — Provides 120 volts output at
25 amps.
29. Starter Switch — With key inserted turn clockwise to
start engine.
22. Receptacle G.F.C.I. — This receptacle provides 120
volts output at 20 amps.
30. Oil Filter — Provides oil filtering for the engine.
23. GFCI Circuit Breaker — This single pole circuit
breaker provides circuit protection (120V @20 amps)
for the G.F.C.I receptacle.
NOTICE
This KUBOTA engine is equipped with a low oil
shutdown capability. A built in sensor will automatically
turn off the engine should the oil level fall below a safe
operating condition. Make sure the generator is placed
on level ground. Placing the generator on level ground
will ensure that the low oil sensor will function properly.
24. Main Circuit Breaker — This 2-pole circuit breaker
provides circuit protection (265V @25 amps) for the
Electric Parts Assembly.
25. AC Voltmeter — This voltmeter indicates (with a
mark) the rated 60 Hz (single-phase) output voltage.
In addition the voltmeter can also be used as a
diagnostic tool. If the voltmeter indicator (needle) is
PAGE 20 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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COMPONENTS (ENGINE)
Figure 5. Kubota Z482 Series
INITIAL SERVICING
8. Cooling Fan Blades — Make sure cooling fan blades
are not bent or broken.A damaged fan blade can cause
the engine to run hot and overheat.
The engine (Figure 5) must be checked for proper
lubrication and filled with fuel prior to operation. Refer to
the manufacturer's engine manual for instructions and
details of operation and servicing.
9. Fan V-Belt — ALWAYS make sure V-belt is properly
tensioned. A loose or defective V-belt can adversely
affect the performance of the generator.
1. Water Drain Cock — Open this cock to drain water
2. Fuel Filter — Prevents dirt and other debris from
entering the fuel system.Replace filter as recommended
in the maintenance section of this manual.
10. Oil Drain Plug/Crankcase — Remove to drain
crankcase oil. Fill with recommended type oil as listed
inTable 5. Crankcase holds a maximum of 2.64 quarts
(2.5 liters) of motor oil.
3. Fuel Feed Pump — Pumps fuel to the injection system.
4. Oil Dip Stick/Gauge — Remove to check amount
and condition of oil in crankcase. Refill or replace with
recommended type oil as listed in Table 5.
11. Starter — Starts engine when ignition key is rotated
to the "ON" position
12. Oil Filter — Spin-on type, filters oil contaminants.
Replace filter as recommended in the maintenance
section of this manual.
5. Speed Control Lever — Controls engine speed.This
lever is factory set. DO NOT adjust this lever.
6. Injector Pump — Provides fuel under pressure to the
injector nozzles.
13. Oil Pressure Switch — Monitors engine oil pressure.
In the event of low oil pressure engine will shutdown.
7. Air Filter — Prevents dirt and other debris from
entering the fuel system. Loosen clips on side of air
filter cannister to gain access to filter element.Replace
with only manufactures recommended type air cleaner.
14. Alternator — Provides power to the +12VDC electrical
system.Replace with only manufactures recommended
type alternator.
15. Oil Filler Cap — Fill with recommended type oil as
listed in Table 5.
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 21
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LOAD APPLICATIONS
Single Phase Load — 60 Hz
To determine the running wattage for your load, multiply the
running wattage as indicated by steps 1, 2, and 3 below:
Always be sure to check the nameplate on the generators
and equipment to insure the wattage, amperage and
frequency requirements are satisfactorily supplied by the
generators for operating the equipment.
1. INCANDESCENT LOADS
Lights, heaters and similar appliances.
total the running wattage and multiply by 1.
Example:
Generally, the wattage listed on the nameplate of the
equipment is its rated output. Equipment may require
130—150% more wattage than the rating on the nameplate,
as the wattage is influenced by the efficiency, power factor
and starting system of the equipment.
29 light bulbs @ 100W each = 2.9 kW
use a 3 kW generator.
2. SMALL MOTORS
Drills and other small power tools.
Total the running wattage and multiply by 2.
Example:
NOTICE
A 1 inch drill runs at 1 kW
use a 2 kW generator
If wattage is not given on the equipment's name plate,
approximate wattage may be determined by multiplying
nameplate voltage by the nameplate amperage
3. LARGE MOTORS
Submersible pumps, table saws etc.
Total the running wattage and multiply by 3.
Example:
A conveyor belt runs at 8 kW
use a 24 kW generator.
WATTS = VOLTAGE x AMPERAGE
The power factor of this generators is 1.0 SeeTable 3 below
when connecting loads.
Table 3. Power Factor By Load
Type Of Load
Power Factor
NOTICE
Single-phase induction motors
0.4 - 0.75
Motors and motor-driven equipment draw much greater
current for starting than during operation. Always use
an adequate size extension cable which can carry the
required load.
Electric heaters, incandescent
lamps
1.0
Fluorescent lamps, mercury
lamps
0.4 - 0.9
Electronic devices,
communication equipment
Extension Cables
1.0
0.8
When electric power is to be provided to various tools or
loads at some distance from the generator, extension cords
are normally used. Cables should be sized to allow for
distance in length and amperage so that the voltage drop
between the generators and point of use (load) is held
to a minimum. Use the cable selection chart (Table 4) as a
guide for selecting proper cable size.
Common power tools
NOTICE
When using a combination of dual receptacles, total
load should not exceed the rated capacity of the
generator.
NOTICE
NOTICE
The idle control device is operated at a minimum load
capacity of 100W.If the load capacity is less than 100W,
place the idle control switch in the OFF position.
When connecting power tools or equipment pay close
attention to the required starting current capacity.
PAGE 22 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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INSPECTION/SETUP
GENERAL INSPECTION PRIOR TO OPERATION
Ground Power Tools
NOTICE
Double-insulated power tools and small appliances
have specially insulated housings that eliminate the
need for a ground. These types of double-insulated
power cords are designed so that no part of the device
will be electrically live even if the internal insulation fails.
When using power tools or electrical equipment requireing
AC power from the generator, make sure power tool cord
has a ground pin or is double insulated as shown in Figure 6.
Extension Cable
When electric power is to be provided to various tools or
loads at some distance from the generator, extension cords
are normally used. Cables should be sized to allow for
distance in length and amperage so that the voltage drop
between the generator and point of use (load) is held to a
minimum.Use the cable selection chart (Table 4) as a guide
for selecting proper cable size.
DANGER
NEVER use power tools or equipment that do not
have a ground capability, the possibility exists of
electrocution, electrical shock or burn, which can cause
severe bodily harm or even DEATH!
Circuit Breakers
ALWAYS place the main, and GFCI circuit breakers in the
OFF position prior to starting the engine.
Figure 6. Ground Pin
Table 4. Cable Selection (60 Hz, Single Phase Operation)
Load In Watts
Maximum Allowable Cable Length
Current In
Amperes
120 Volts 240 Volts
#10 Wire
1000 ft.
500 ft.
350 ft.
250 ft.
150 ft.
125 ft.
#12 Wire
600 ft.
300 ft.
200 ft.
150 ft.
100 ft.
75 ft.
#14 Wire
375 ft.
200 ft.
125 ft.
100 ft.
65 ft.
#16 Wire
250 ft.
2.5
5
300
600
600
1200
1800
2400
3600
4800
125 ft.
7.5
10
15
20
900
100 ft.
1200
1800
2400
50 ft.
CAUTION: Equipment damage can result from low voltage.
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 23
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INSPECTION/SETUP
4. If the oil level is low, remove the oil filler cap (Figure 9)
and fill to a safe operating level (max) as indicated by
the dipstick. Fill with recommended type oil as listed in
Table 5.Maximum oil capacity is 2.64 quarts (2.5 liters).
Before Starting
1. Read safety instructions at the beginning of manual.
2. Clean the generator, removing dirt and dust, particularly
the engine cooling air inlet.
3. Check the air filter for dirt and dust. If air filter is dirty,
replace air filter with a new one as required.
4. Check fastening nuts and bolts for tightness
Engine Oil Check
1. To check the engine oil level, place the generator on
secure level ground with the engine stopped.
2. Remove the dipstick from its holder (Figure 7) and wipe
clean.
Figure 9. Engine Oil Filler Port
Table 5. Oil Type
Temperature
Oil Type
SAE 30 or SAE10W-30
SAE 15W-40
Above 77° F (25° C)
32°~ 77° F
(0° ~ 25° C)
SAE 20 or SAE10W-30
SAE 15W-40
Figure 7. Engine Oil Dipstick Removal
3. Re-Insert dipstick (Figure 8), then remove dipstick from
its holder. Check the oil level shown on the dipstick.
SAE 10 or SAE10W-30
SAE 15W-40
Below 32° F (0° C)
Figure 8. Engine Oil Dipstick
PAGE 24 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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INSPECTION/SETUP
NOTICE
NOTICE
When refueling, be sure to use a strainer for filtration.
DO NOT top-off fuel. DO NOT fill the tank beyond
capacity. Wipe up any spilled fuel immediately!
When adding engine oil DO NOT overfill.
Fuel Check
Coolant (Antifreeze)
Fill the fuel tank with #2 diesel fuel. DO NOT fill the tank
beyond capacity.
Kubota recommends Antifreeze/Summer Coolant for use
in thier engines, which can be purchased in concentrate
(and mixed with 50% demineralized water) or pre-diluted.
See the Kubota Engine Owner's Manual for further details
Pay attention to the fuel tank capacity when replenishing
fuel. Refer to the fuel tank capacity listed in Table 2.
The fuel tank cap must be closed tightly after filling.Handle
fuel in a safety container. If the container does not have a
spout, use a funnel.
WARNING
If adding coolant/antifreeze mix to the
radiator, DO NOT remove the radiator cap
until the unit has completely cooled. The
possibility of hot! coolant exists which can
cause severe burns
1. Read the fuel gauge located on top of the generator
(Figure 10) to determin if the fuel level is low.
Day-to-day addition of coolant is done from the recovery
tank.When adding coolant to the radiator, DO NOT remove
the radiator cap until the unit has completely cooled. See
Table 6 for engine, radiator, and recovery tank coolant
capacities.Make sure the coolant level in the recovery tank
is always between the "H" and the "L" markings.
Figure 10. Fuel Gauge
2. If fuel is low, remove the fuel cap (Figure 11) located
on top of the generator and replenish with clean #2
diesel fuel.
Table 6. Coolant Capacity
Engine and Radiator
Reserve Tank (Full)
.74 gal (2.8 liters)
.23 gal (.87 liters)
Operation Freezing Weather
When operating in freezing weather, be certain the proper
amount of antifreeze (Table 7) has been added.
Table 7. Anti-Freeze Operating
Temperatures
Freezing Point
Vol %
Figure 11. Adding Fuel
Anti-Freeze
°C
°F
DANGER
50
-37
-34
Motor fuels are highly flammable and can
be dangerous if mishandled. DO NOT
smoke while refueling. DO NOT attempt
to refuel the generator if the engine is hot!,
running or in the dark.
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 25
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INSPECTION/SETUP
BATTERY
NOTICE
This unit is of negative ground DO NOT connect in reverse.
Always maintain battery fluid level between the specified
marks. Battery life will be shortened, if the fluid level are
not properly maintained. Add only distilled water when
replenishment is necessary.
When the antifreeze is mixed with water, the antifreeze
mixing ratio must be less than 50%.
CLEANING THE RADIATOR
The engine may overheat if the radiator fins become
overloaded with dust or debris. Periodically clean the
radiator fins with compressed air. Cleaning inside the
machine is dangerous, so clean only with the engine turned
off and the negative battery terminal disconnected.
DO NOT over fill. Check to see whether the battery
cables are loose. Poor contact may result in poor starting
or malfunctions. Always keep the terminals firmly
tightened. Coating the terminals with an approved battery
terminal treatment compound. Replace battery with only
recommended type battery.
AIR CLEANER
The battery is sufficiently charged if the specific gravity
of the battery fluid is 1.28 (at 68° F). If the specific gravity
should fall to 1.245 or lower, it indicates that the battery is
dead and needs to be recharged or replaced.
Periodic cleaning/replacement is necessary. Inspect it in
accordance with the KUBOTA Engine Owner’s Manual.
Fan Belt Tension
A slack fan belt may contribute to overheating, or to
insufficient charging of the battery. Inspect the fan belt
for damage and wear and adjust it in accordance with the
Kubota Engine Owner's Manual.
Before charging the battery with an external electric source,
be sure to disconnect the battery cables.
Battery Cable Installation
ALWAYS be sure the battery cables (Figure 13) are properly
connected to the battery terminals as shown below. The
red cable is connected to the positive terminal of the
battery, and the black cable is connected to the negative
terminal of the battery.
The fan belt tension is proper if the fan belt bends 10 to 15
mm (Figure 12) when depressed with the thumb as shown
below.
CAUTION
ALWAYS disconnect the negative terminal FIRST and
reconnect negative terminal LAST.
Figure 12. Fan Belt Tension
CAUTION
NEVER place hands near the belts or fan
while the generator set is running.
Figure 13. Battery Connections
PAGE 26 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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INSPECTION/SETUP
When connecting battery do the following:
1. NEVER connect the battery cables to the battery
terminals when the Ignition Switch is in the START
position.ALWAYS make sure that the Ignition Switch
is in the OFF position when connecting the battery.
2. Place a small amount of battery terminal treatment
compound around both battery terminals. This will
ensure a good connection and will help prevent
corrosion around the battery terminals.
NOTICE
If the battery cable is connected incorrectly, electrical
damage to the generator will occur. Pay close attention
to the polarity of the battery when connecting the battery.
CAUTION
Inadequate battery connections may cause poor
starting of the generator, and create other malfunctions.
ALTERNATOR
The polarity of the alternator is negative grounding type.
When an inverted circuit connection takes place, the
circuit will be in short circuit instantaneously resulting the
alternator failure.
DO NOT put water directly on the alternator. Entry of water
into the alternator can cause corrosion and damage the
alternator.
WIRING
Inspect the entire generator for bad or worn electrical wiring
or connections. If any wiring or connections are exposed
(insulation missing) replace wiring immediately.
PIPING AND HOSE CONNECTION
Inspect all piping, oil hose, and fuel hose connections for
wear and tightness. Tighten all hose clamps and check
hoses for leaks.
If any hose (fuel or oil) lines are defective replace them
immediately.
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 27
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OPERATION
3. NEVER start the engine with the main circuit breaker
in the ON position.Alwaysplace circuit breaker (Figure 16)
in the OFF position before starting.
Before Starting the Engine
CAUTION
The engine’s exhaust contains harmful emissions.
ALWAYS have adequate ventilation when operating.
Direct exhaust away from nearby personnel.
OFF
OFF
25A
25A
WARNING
NEVER manually start the engine with the main or GFCI
circuit breakers in the ON (closed) position.
Figure 16. Main Circuit Breaker (OFF)
4. NEVER start the engine with the GFCI circuit breaker
in the ON position.Always place circuit breaker (Figure
17) in the OFF position before starting the engine.
1. Open the cabinet door and turn the fuel cock lever
(Figure 14) to the “ON” position.
Figure 17. GFCI Circuit Breaker (OFF)
Starting the Engine
1. Insert the key into the starter switch (Figure 18) and
turn it to the “RUN” position. Check to see that the oil
pressure and charge Lights on the "Warning Lamp
Unit Display " are lit. If either light is not lit, check the
system and wiring (refer to the Engine Operation
Manual).
Figure 14. Fuel Cock Lever (ON)
2. NEVER operate the generator with the doors open
(Figure 15). Operation with the doors open may cause
insufficient cooling of the unit, and engine damage may
result. Close the doors for normal operation.
W
7KW
Mod
HIS
AC
PE
RW
AT
T
WHISPERW
AT
T
7KW
AC
Model
el
D
A-70
00S
S
DA-7000SS
ON
ON
OF
RUN
STO
P
HEA
T
OFF
RUN
HEA
T
STO
P
IDLE
CONT
AC
V
ROL
F
OL
T
MET
AC
BRE
C
AKE
ER
IDLE
CONTR
OL
IRCU
R
IT
AC
VOL
TMETE
A
C
CI
BREA
R
RCU
IT
KER
ST
A
000
HOUR
RT
0
0
700
DIE
0
SEL
W
S
T
A
TT
AR
T
0
00
S
0
0
7000
WA
T
T
POW
POW
HO
ERE
STAR
TER
URS
D
A
HOUR
D
IE
SEL
C
G
MET
SWITCH
ENE
ER
RATO
R
ERED
H
STAR
7000
AC
OUR ME
TER SWITCH
GEN
ERA
TOR
TER
T
T
A
WHISPERW
25A
25A
25A
25A
25A
120/240V
25A
25A
1
20/2
40V
25A
120/240V
120
/24
0V
Figure 18. Starter Switch
2. Turn the ignition key to the HEAT position. When the
preheat light goes off, turn the key to the START
position to start the engine. As soon as the engine
starts, release the key. The key will automatically return
to the RUN position.
CORRECT
Figure 15. Generator Doors
3. During winter or when the surrounding air temperature
is cold, in situations where a load start is required, turn
the key to the HEAT position, you must wait until the
preheat light goes off.
PAGE 28 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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OPERATION
2. Place GFCI circuit breaker (Figure 21) in the ON
position.
4. If the engine does not start within 10 seconds after the
key is turned to the START position, wait for about 30
seconds and repeat the procedure as described in
step 4. above.
5. When the engine starts, the oil pressure light and
charge light should go out. If these lights stay on,
immediately stop the engine and check the system and
wiring (refer to the Engine Operation Manual).
Figure 21. GFCI Circuit Breaker (ON)
6. Let the engine idle for five minutes with the Idle Control
Switch (Figure 19) placed in the ON position.
3. Read voltmeter on front panel of generator (Figure 22)
and verify that 120VAC is displayed.Using an external
voltmeter as shown in Figure 22, verify that 120 VAC
is present at the 120V twist-lock and GFCI duplex
receptacles.
Figure 19. Idle Control Switch (ON)
NOTICE
Placing the idle control switch (Figure 19) in the OFF
position allows the engine to operate at a maximum
speed of about 3600 RPM's.
When the idle control switch is placed in the up position
(ON), the generator will run at idle speed (2200 RPM's)
until a load is applied, at that time the engine speed
will increase to 3600 RPM's as long as a load is being
applied.
When the load is not in use, the engine speed will drop
back to the idle mode after about 3 seconds.
Output Voltage Verification
Figure 22. 120V GFCI/L5-30R Receptacles
1. Place main circuit breaker (Figure 20) in the ON
position.
NOTICE
When using a combination of dual receptacles, total
load should not exceed the rated capacity of the
generator.
ON
ON
25A
25A
Figure 20. Main Circuit Breaker (ON)
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 29
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OPERATION/SHUTDOWN
4. The CS-6369 receptacle is a dual voltage receptacle
(120/240 volts). Using an external voltmeter as shown
in Figure 23, verify that 120/240 VAC is present at the
CS-6369 twist-lock receptacle..
Stopping the Engine (Normal Shutdown)
1. Place main circuit breaker (Figure 25) in the OFF
position.
OFF
25A
OFF
25A
Figure 25. Main Circuit Breaker (OFF)
2. Place GFCI circuit breakers (Figure 26) in the OFF
positing.
Figure 26. GFCI Circuit Breakers (OFF)
3. Place idle control switch switch (Figure 27) in the ON
position.
Figure 23. 120/240 CS-6369 Receptacle
5. The L14-30R receptacle is a dual voltage receptacle
(120/240 volts). Using an external voltmeter as shown
in Figure 24, verify that 120/240 VAC is present at the
L14-30R twist-lock receptacle.
Figure 27. Idle Control switch (OFF)
4. Let engine run at idle with no load for 3-5 minutes.
5. Place the starter switch key (Figure 28) in the STOP
position and remove the key. Place fuel cock lever in
the OFF position.
Figure 28. Starter Switch (Stop Position)
6. Remove all loads from the generator.
Emergency Shutdown
Figure 24. 120/240V L14-30R Receptacle
6. Connecting of loads (power tools, lighting ect.) to the
generator receptacles can now be done.
1. Place starter switch key in STOP position.Remove key.
Place fuel cock lever in the OFF position.
PAGE 30 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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PREPARATION FOR LONG TERM STORAGE
Generator Storage
For storage of the generating set for over 30 days, the
following is required:
Run the engine until all the fuel is completely consumed.
Drain the fuel tank completely, or add STA-BIL to the fuel
Completely drain the oil from the crankcase and refill
with fresh oil.
Disconnect the negative battery cable from the battery.
Clean all external parts of the generating set with a cloth.
If generator is mounted on a trailer, jack trailer up and
place on blocks so tires do not touch the ground or block
and completely remove the tires.
Cover the generating set and store in a clean, dry
place.
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 31
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MAINTENANCE
Use Table 8as a general maintenance guideline when
servicing your engine.For more detail engine maintenance
information, refer to the engine owner's manual supplied
with your engine.
Table 8. Engine Maintenance Schedule
EVERY
2YEARS
OR
EVERY 8
YEARS
OR
FIRST
DAILY MONTH OR MONTHS
EVERY 3
EVERY 6
MONTHS
OR 25 HRS. OR 50 HRS. 100 HRS.
EVERY
YEAR OR
DESCRIPTION
(3)
OPERATION
50 HRS.
200 HRS. 800 HRS.
CHECK
X
Engine Oil
CHANGE
X
X
Oil Filter
Cartridge
CHANGE
X
CHECK
X
X
Air Cleaner
Element
CHANGE
X(1)
RETIGHTEN IF
NECESSARY
All Nuts & Bolts
Cooling Fins
Fuel Tank
CHECK
CLEAN
CLEAN
X
X
X
X
Fuel Filter
X
Fuel Filter
Element
CHANGE
Fuel lines
Battery
CHANGE
CHANGE
Every 2 years, replace if necessary (2)
Every 2 years, replace if necessary (2)
Radiator Hoses/
Clamps
CHANGE
Radiator
Coolant
CHANGE
X
Idle Speed
CHECK-ADJUST
X (2)
Valve Clearance CHECK-ADJUST
X (2)
(1) Service more frequently when used in DUSTY areas.
(2) These items should be serviced by your service dealer, unless you have the proper tools and are mechanically
proficient. Refer to the KUBOTA Shop Manual for service procedures.
(3) For commercial use, log hours of operation to determine proper maintenance intervals.
NOTICE
Thoroughly remove dirt and oil from the engine and
control area. Clean or replace the air cleaner elements
as necessary. Check and retighten all fasteners as
necessary..
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MAINTENANCE
2. Screw on new oil filter by hand until seal contacts the
filter mounting base. Install drain bolt with sealing
washer and hand tighten.
Maintenance
Perform the scheduled maintenance procedures as defined
by Table 8 and below:
NOTICE
Engine Oil
When installing the oil filter, coat rubber seal with a
small amount of lubricant (motor oil). DO NOT over-
tighten cartridge. Hand tighten only.
Every 100 hours:Change engine oil after the first 50 hours
of operation and 100 hours thereafter. Always check the
crankcase oil level prior to each use, or when the fuel tank
is filled. Insufficient oil may cause severe engine damage.
Make sure generator is level when checking oil level. The
oil level must be between the two notches on the dipstick
as shown in Figure 8.
3. Replace engine oil with recommended type oil as listed
in Table 5. For engine oil capacity, see Table 2 (engine
specifications). Fill to upper limit as shown in Figure 8.
Engine Air Cleaner
1. Remove engine oil drain plug located at the bottom of
the generator enclosure (Figure 29) and drain oil from
crankcase.For best results drain oil while engine is
warm. Reinstall oil drain plug, and add engine oil as
specified in Table 5. Crankcase oil capacity is 2.64 qts.
(2.5 liters).
Every 50 hours: The air cleaner employed on the
KUBOTA Z482 series engines is a dry type, NEVER
apply oil to it.If generator is used in severe dusty areas
service air cleaner element more frequently.
1. Release the air cleaner retaining clamps (Figure 31)
and remove the air cleaner element.
Figure 29. Engine Oil Drain Plug
Figure 31. Air Cleaner
Oil Filter Cartridge
2. Wipe the inside of the air cleaner with a clamp cloth and
remove all dust and debris that may have accumulated
inside air cleaner body.
Every 200 hours: Replace the engine oil filter cartridge
after every 200 hours of operation.
1. Clean oil filter mounting base, and coat oil filter seal
(Figure 30) with clean engine oil.
3. Tap the edge of element lightly to allow heavy dust
build-up to fall off.
4. Tap the paper filter element (Figure 31) several times on
a hard surface to remove dirt, or blow compressed air
[not exceeding 99 psi (686 kPa, 2.1 kgf/cm2)] through
the filter element from from the inside while turning
the element. NEVER brush off dirt. Brushing will force
dirt into the fibers.
5. Replace the filter element once a year or every six
cleanings or if it is excessively dirty
Figure 30. Oil Filter Cartridge
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 33
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MAINTENANCE
Cleaning the Fuel Filter
Radiator
Every 100 hours: Clean fuel filter every 100 hours of
operation or once a month to remove dust or water.
Check Daily: Always check the level of the coolant in the
radiator before starting the engine. Remove the radiator
cap and verify that the coolant reaches top of radiator coils.
1. Place fuel cock lever (Figure 32) in the close position.
2. Disconnect fuel lines from fuel filter.
1. DO NOT remove the radiator cap while the coolant is
hot. The possibility exists of severe burns or scalding
from the coolant gushing out. Let the coolant cool
before removing radiator cap.
2. Check coolant in the reserve tank daily (Figure 34).
Make sure the level is between the FULL (H) and LOW
(L) markings. Fill reserve tank with a mixture of 50/50
antifreeze/water.
Figure 32. Fuel Cock Lever (OFF)
Replacing Fuel Filter Element
Every 200 hours: Replace fuel filter element.
1. Remove the top cap (Figure 33) from the fuel filter and
rinse cap and filter bowl with diesel fuel.
2. Remove element, and rise with diesel fuel.
3. Reinstall fuel filter and connect fuel lines.
Figure 34. Radiator/Reserve Tank
Flushing Out Radiator and Replacing Coolant
1. Remove radiator coolant plug (Figure 35) located at
the bottom of the generator enclosure and drain
radiator coolant. Open the radiator cap while draining.
Remove the overflow tank and drain.
COOLANT DRAIN
COOLANT DRAIN
PLUG
OIL RAIN
Figure 33. Fuel Filter Disassembly
4. Inspect all fuel lines every 50 hours.
Figure 35. Coolant Drain Plug
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MAINTENANCE
2. Flush the radiator by running clean tap water through
radiator until signs of rust and dirt are removed. DO
NOT clean radiator core with any objects, such as a
screwdriver.
GENERATOR STORAGE
For long term storage of the generator the following is
recommended:
Drain the fuel tank completely.Treat with a fuel stabilizer
if necessary.
3. Check hoses for softening and kinks. Check clamps
for signs of leakage.
Completely drain the oil from the crankcase and refill if
necessary with fresh oil.
4. Tighten coolant drain plug and reinstall the overflow
tank.
Clean the entire generator, internal and external.
Cover the generating set and store in a clean, dry place.
Disconnect the negative battery cable from the battery.
Make sure engine coolant is at proper level.
5. Fill with coolant as recommended by the engine
manufacturer.
6. Close radiator cap tightly.
WARNING
Allow engine to cool when flushing out
radiator. Flushing the radiator while hot
could cause serious burns from water or
steam.
If generator is mounted on a trailer, jack trailer up and
place on blocks so tires do not touch the ground or block
and completely remove the tires.
RADIATOR CLEANING
The radiator (Figure 36) should be sprayed (cleaned) with
a high pressure washer when excessive amounts of dirt
and debris have accumulated on the cooling fins or tube.
When using a high pressure washer, stand at least 5 feet
(1.5 meters) away from the radiator to prevent damage to
the fins and tube.
Figure 36. Radiator Cleaning
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 35
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MAINTENANCE (TRAILER)
Follow the steps below to disassemble the wheel hub and
service the wheel bearings. See Figure II.
TRAILER MAINTENANCE
The following trailer maintenance guidelines are intended
to assist the operator in preventive maintenance.
BEARING
WHEEL
HUB
Adjustable Channel
OIL
SEAL
COTTER
BEARING
PIN
CUP
BEARING
Your trailer may be equipped with an adjustable channel
(Figure I) that allows the coupler to be raised or lowered
to a desired height. Periodically check the channel bolts
for damage or loosening.
BEARING
CUP
DUST
CAP
LUG
NUT
SPINDLE
WASHER
SPINDLE
NUT
Figure II. Wheel Hub Components
After removing the dust cap, cotter pin, spindle nut and
spindle washer, remove the hub to inspect the bearings
for wear and damage.
Replace bearings that have flat spots on rollers, broken
roller cages, rust or pitting. Always replace bearings
and cups in sets. The inner and outer bearings are to
be replaced at the same time.
Figure I. Adjustable Channel
Replace seals that have nicks, tears or wear.
Wheel Bearings
Lubricate the bearings with a high quality EP-2
automotive wheel bearing grease.
Wheel bearings (Figure II) must be inspected and
lubricated once a year or 12,000 miles to insure safe
operation of your trailer.
Wheel Hub Adjustment
Every time the wheel hub is removed and the bearings are
reassembled, follow the steps below to check the wheel
bearings for free running and adjust.
If trailer wheel bearings are immersed in water, they must
be replaced.
DANGER
Turn the hub slowly, by hand, while tightening the spindle
nut until you can no longer turn the hub by hand.
If trailer wheels are under water for a long period of
time, wheel bearings may fail.If this is the case, service
wheel bearings immediately.
Loosen the spindle nut just until you are able to turn it
(the spindle nut) by hand. Do not turn the hub while the
spindle nut is loose.
The possibility exists of the wheels falling off causing
equipment damage and severe bodily harm even death!
Install a new cotter pin through the spindle nut and
axle.
If the trailer has not been used for an extended amount
of time, have the bearings inspected and packed more
frequently, at least every six months and prior to use.
Check the adjustments.Both the hub and the spindle nut
should be able to move freely (the spindle nut motion
will be limited by the cotter pin).
PAGE 36 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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MAINTENANCE (TRAILER)
Leaf Suspension
DANGER
The leaf suspension springs and associated components
(Figure III) should be visually inspected every 6,000 miles
for signs of excessive wear, elongation of bolt holes, and
loosening of fasteners. Replace all damaged parts
(suspension) immediately.
NEVER crawl under the trailer unless it is on firm
and level ground and resting on properly placed and
secured jackstands.
The possibility exists of the trailer falling thus causing
equipment damage and severe bodily harm even death!
AXLE
U-BOLT
DANGER
HANGER SUPPORT
BRACKET IS WELDED
TO FRAME
When performing trailer inspection and maintenance
activities, you must jack up the trailer using jacks and
jackstands.
LEAF
SUSPENSION
FRONT
When jacking and using jackstands, place them so
as to clear wiring, brake lines, and suspension parts
(i.e., springs, torsion bars). Place jacks and jackstands
inside of the perimeter strip on the supporting structure
to which the axles are attached.
HANGER NUT
FRONT
HANGER BOLT
U-BOLT
LOCKING
NUT
TIE PLATE
Figure III. Leaf Suspension Components
DANGER
Improper weld repair will lead to early failure of the
trailer structure and can cause serious injury or death.
DANGER
Worn or broken suspension parts can cause loss of
control, damage to equipment and severe bodily injury,
even death!
DO NOT repair cracked or broken welds unless you
have a certified welder perform the repair. If not, have
the welds repaired by your dealer.
Check suspension regularly.
WARNING
If the trailer is involved in an accident, have it inspected
immediately by qualified personnel. In addition, the
trailer should be inspected annually for signs of wear
or deformations.
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 37
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TRAILER GUIDELINES
The following guidelines are intended to assist the operator
in the operation and handling of a trailer.
Shift your automatic transmission into a lower gear for
city driving.
Safety precautions should be followed at all times when
operating a trailer. Failure to read, understand and follow
the safety guidelines could result in injury to yourself and
others.Loss of control of the trailer or tow vehicle can result
in death or serious injury.
ALWAYS use lower gears for climbing and descending
grades.
DO NOT ride the brakes while descending grades, they
may get so hot that they stop working. Then you will
potentially have a runaway tow vehicle and trailer.
COMMON CAUSES FOR LOSS OF TRAILER
To conserve fuel, don’t use full throttle to climb a hill.
Instead, build speed on the approach.
Driving too fast for the conditions (maximum speed when
towing a trailer is 55 mph).
Slow down for bumps in the road. Take your foot off the
brake when crossing the bump.
Overloading the trailer or loading the trailer unevenly.
Trailer improperly coupled to the hitch.
No braking on trailer.
DO NOT brake while in a curve unless absolutely
necessary. Instead, slow down before you enter the
curve and power through the curve.This way, the towing
vehicle remains in charge.
Not maintaining proper tire pressure.
Not keeping lug nuts tight.
DO NOT apply the brakes to correct extreme trailer
swaying. Continued pulling of the trailer, and even slight
acceleration, will provide a stabilizing force.
Not properly maintaining the trailer structure.
Ensure machine is towed level to tow vehicle.
TRAILER TOWING GUIDELINES
Anticipate the trailer “swaying.” Swaying is the trailer
reaction to the air pressure wave caused by passing
trucks and buses.Continued pulling of the trailer provides
a stabilizing force to correct swaying. DO NOT apply the
brakes to correct trailer swaying.
Recheck the load tiedowns to make sure the load will
not shift during towing.
Use lower gear when driving down steep or long grades.
Use the engine and transmission as a brake. Do not
ride the brakes, as they can overheat and become
ineffective.
Before towing, check coupling, safety chain, safety
brake, tires, wheels and lights.
Check the lug nuts or bolts for tightness.
Check coupler tightness after towing 50 miles.
Be aware of your trailer height, especially when
approaching roofed areas and around trees.
Use your mirrors to verify that you have room to change
lanes or pull into traffic.
Make regular stops, about once each hour. Confirm
that:
Use your turn signals well in advance. Allow plenty of
stopping space for your trailer and tow vehicle.
• Coupler is secure to the hitch and is locked.
• Electrical connectors are secure.
Allow plenty of stopping space for your trailer and tow
vehicle.
• There is appropriate slack in the safety chains.
DO NOT drive so fast that the trailer begins to sway
due to speed.
• There is appropriate slack in the breakaway switch
pullpin cable.
Allow plenty of room for passing. A rule of thumb is that
the passing distance with a trailer is 4 times the passing
distance without the trailer.
• Tires are not visibly low on pressure.
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TRAILER GUIDELINES
for the use of your trailer. Again, be sure your hitch and tow
vehicle are rated for the Gross Vehicle Weight Rating of
your trailer.
DRIVING CONDITIONS
When towing a trailer, you will have decreased acceleration,
increased stopping distance, and increased turning radius
(which means you must make wider turns to keep from
hitting curbs, vehicles, and anything else that is on the
inside corner). In addition, you will need a longer distance
to pass, due to slower acceleration and increased length.
WARNING
Proper selection and condition of the coupler and hitch
are essential to safely towing your trailer. A loss of
coupling may result in death or serious injury.
Be alert for slippery conditions.You are more likely to be
affected by slippery road surfaces when driving a tow
vehicle with a trailer, than driving a tow vehicle without
a trailer.
• Be sure the hitch load rating is equal to or greater
than the load rating of the coupler.
• Be sure the hitch size matches the coupler size.
• Observe the hitch for wear, corrosion and cracks
before coupling. Replace worn, corroded or cracked
hitch components before coupling the trailer to the
tow vehicle.
Check rearview mirrors frequently to observe the trailer
and traffic.
NEVER drive faster than what is safe.
• Be sure the hitch components are tight before
coupling the trailer to the tow vehicle.
WARNING
Driving too fast for severe road conditions can result in
loss of control and cause death or serious injury.
WARNING
An improperly coupled trailer can result in death or
serious injury.
Decrease your speed as road, weather, and lighting
conditions deteriorate.
DO NOT move the trailer until:
Always check for local trailer tow speed limits in your
area.
• The coupler is secured and locked to hitch.
• The safety chains are secured to the tow vehicle.
• The trailer jack(s) are fully retracted.
WARNING
Do not transport people on the trailer.The transport of
people puts their lives at risk and may be illegal.
DO NOT tow the trailer on the road until:
• Tires and wheels are checked.
COUPLING TO THE TOW VEHICLE
• The trailer brakes are checked.
• The breakaway switch is connected to the tow vehicle.
• The load is secured to the trailer.
Follow all of the safety precautions and instructions in
this manual to ensure safety of persons, equipment, and
satisfactory life of the trailer. Always use an adequate tow
vehicle and hitch. If the vehicle or hitch is not properly
selected and matched to the Gross Vehicle Weight Rating
(GVWR) of your trailer, you can cause an accident that
could lead to death or serious injury.
• The trailer lights are connected and checked.
WARNING
Use of a hitch with a load rating less than the load rating
of the trailer can result in loss of control and may lead
to death or serious injury.
If you already have a tow vehicle, know your vehicle tow
rating and make certain the trailer’s rated capacity is less
than or equal to the tow vehicle’s rated towing capacity. If
you already have (or plan to buy) a trailer, make certain
that the tow rating of the tow vehicle is equal to or greater
than that of the trailer.
Use of a tow vehicle with a towing capacity less than
the load rating of the trailer can result in loss of control,
and may lead to death or serious injury.
Be sure your hitch and tow vehicle are rated for the
Gross Vehicle Weight Rating of your trailer.
The trailer VIN tag contains the critical safetyinformation
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 39
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TRAILER GUIDELINES
Drive slowly at first, 5 mph or so, and turn the wheel to
get the feel of how the tow vehicle and trailer combination
responds. Next, make some right and left hand turns.
Watch in your side mirrors to see how the trailer follows
the tow vehicle. Turning with a trailer attached requires
more room.
INOPERABLE BRAKES, LIGHTS OR MIRRORS
Be sure that the brakes and all of the lights on your trailer
are functioning properly before towing your trailer. Check
the trailer taillights by turning on your tow vehicle headlights.
Check the trailer brake lights by having someone step on
the tow vehicle brake pedal while you look at trailer lights.
Do the same thing to check the turn signal lights.SeeTrailer
Wiring Diagram section in this manual.
Stop the rig a few times from speeds no greater than
10 mph. If your trailer is equipped with brakes, try using
different combinations of trailer brake and tow vehicle brake.
Note the effect that the trailer brakes have when they are
the only brakes used. When properly adjusted, the trailer
brakes will come on just before the tow vehicle brakes.
Standard mirrors usually do not provide adequate visibility
for viewing traffic to the sides and rear of a towed trailer.
You must provide mirrors that allow you to safely observe
approaching traffic.
It will take practice to learn how to back up a tow vehicle
with a trailer attached.Take it slow. Before backing up, get
out of the tow vehicle and look behind the trailer to make
sure that there are no obstacles.
WARNING
Improper electrical connection between the tow vehicle
and the trailer will result in inoperable lights and can
lead to collision.
Some drivers place their hands at the bottom of the steering
wheel, and while the tow vehicle is in reverse, “think” of the
hands as being on the top of the wheel. When the hands
move to the right (counterclockwise, as you would do to
turn the tow vehicle to the left when moving forward), the
rear of the trailer moves to the right. Conversely, rotating
the steering wheel clockwise with your hands at the bottom
of the wheel will move the rear of the trailer to the left while
backing up.
Before each tow, check that the tail lights, brake lights
and turn signals work.
TRAILER TOWING TIPS
Driving a vehicle with a trailer in tow is vastly different
from driving the same vehicle without a trailer in tow.
Acceleration, maneuverability and braking are all diminished
with a trailer in tow.
If you are towing a bumper hitch rig, be careful not to allow
the trailer to turn too much because it will hit the rear of the
tow vehicle.To straighten the rig, either pull forward or turn
the steering wheel in the opposite direction.
It takes longer to get up to speed, you need more room to
turn and pass, and more distance to stop when towing a
trailer.You will need to spend time adjusting to the different
feel and maneuverability of the tow vehicle with a loaded
trailer.
TRAILER VIN TAG
Because of the significant differences in all aspects of
maneuverability when towing a trailer, the hazards and risks
of injury are also much greater than when driving without
a trailer.You are responsible for keeping your vehicle and
trailer in control, and for all the damage that is caused if
you lose control of your vehicle and trailer.
Figure A below is a sample of the Vehicle Identification
Number (VIN)Tag which is typically located on the left front
of the trailer. See Figure B for location.
As you did when learning to drive an automobile, find
an open area with little or no traffic for your first practice
trailering.Of course, before you start towing the trailer, you
must follow all of the instructions for inspection, testing,
loading and coupling. Also, before you start towing, adjust
the mirrors so you can see the trailer as well as the area
to the rear of it.
Figure A. Vehicle VIN Tag
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TRAILER GUIDELINES
To determine the “empty” or “net” weight of your trailer,
weigh it on an axle scale. To find the weight of the trailer
using an axle scale, you must know the axle weights of
your tow vehicle without the trailer coupled. Some of the
trailer weight will be transferred from the trailer to the tow
vehicle axles, and an axle scale weighs all axles, including
the tow vehicle axles.
G
A
VIN
T
TOW VEHICLE
The towing hitch attached to your tow vehicle must have a
capacity equal to or greater than the load rating of the trailer
you intend to tow.The hitch capacity must also be matched
to the tow vehicle capacity.Your vehicle dealer can provide
and install the proper hitch on your tow vehicle.
VIN TAG
Figure B. VIN Tag Location
SUSPENSION SYSTEM
The trailer VIN Tag contains the following critical safety
information for the use of your trailer.
Sway bars, shock absorbers, heavy duty springs, heavy
duty tires and other suspension components may be
required to sufficiently tow the trailer and pump.
GAWR:The maximum gross weight that an axle cansupport.
It is the lowest of axle, wheel, or tire rating.
Usually, the tire or wheel rating is lower than the axle rating,
and determines GAWR.
SIDE VIEW MIRRORS
The size of the trailer that is being towed and your state
law regulations determine the size of the mirrors.However,
some states prohibit extended mirrors on a tow vehicle,
except while a trailer is actually being towed. In this
situation, detachable extended mirrors are necessary.
Check with your dealer or the appropriate state agency
for mirror requirements.
GVWR: The maximum allowable gross weight of the trailer
and its contents. The gross weight of the trailer includes
the weight of the trailer and all of the items within it. GVWR
is sometimes referred to as GTWR (Gross Trailer Weight
Rating), or MGTW (Maximum GrossTrailerWeight).GVWR,
GTWR and MGTW are all the same rating.
The sum total of the GAWR for all trailer axles may be less
than the GVWR for the trailer, because some of the trailer
load is to be carried by the tow vehicle, rather than by the
trailer axle(s).The total weight of the cargo and trailer must
not exceed the GVWR, and the load on an axle must not
exceed its GAWR.
HEAVY DUTY FLASHER
A Heavy Duty Flasher is an electrical component that may
be required when your trailer turn signal lights are attached
to the tow vehicle flasher circuit.
ELECTRICAL CONNECTOR
PSIC: The tire pressure (psi) measured when cold.
VIN: The Vehicle Identification Number.
An Electrical Connector connects the lights on the trailer
to the lights on the towing vehicle.
EMPTY WEIGHT: Some information that comes with the
trailer (such as the Manufacturer’s Statement of Origin)
is not a reliable source for “empty” or “net” weight. The
shipping documents list average or standard weights and
your trailer may be equipped with options.
EMERGENCY FLARES ANDTRIANGLE REFLECTORS
It is wise to carry these warning devices even if you are
not towing a trailer.It is particularly important to have these
when towing a trailer because the hazard flashers of your
towing vehicle will not operate for as long a period of time
when the battery is running both the trailer lights and tow
vehicle lights.
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TRAILER GUIDELINES
Check the locking device that secures the coupler to the
ball for proper operation.
SAFETY CHAINS
If the coupler connection comes loose, the safety chains
can keep the trailer attached to the tow vehicle. With
properly rigged safety chains, it is possible to keep the
tongue of the trailer from digging into the road pavement,
even if the coupler-to-hitch connection comes apart.
If you see or feel evidence of wear, such as flat spots,
deformations, pitting or corrosion, on the ball or coupler,
immediately have your dealer inspect them to determine
the proper action to prevent possible failure of the ball and
coupler system. All bent or broken coupler parts must be
replaced before towing the trailer.
JACKSTAND
The coupler handle lever must be able to rotate freely and
automatically snap into the latched position. Oil the pivot
points, sliding surfaces, and spring ends with SAE 30W
motor oil.Keep the ball socket and latch mechanism clean.
Dirt or contamination can prevent proper operation of the
latching mechanism.
A device on the trailer that is used to raise and lower the
coupler.The jack is sometimes called the “landing gear” or
the “tongue jack”.
COUPLER TYPES
Two types of coupler used with the trailer are discussed
below.
The load rating of the coupler and the necessary ball size
are listed on the trailer tongue.You must provide a hitch and
ball for your tow vehicle where the load rating of the hitch
and ball is equal to or greater than that of your trailer.
Ball Hitch Coupler
Pintel Eye Coupler
BALL HITCH COUPLER
Also, the ball size must be the same as the coupler size. If
the hitch ball is too small, too large, is underrated, is loose
or is worn, the trailer can come loose from the tow vehicle
and may cause death or serious injury.
A ball hitch coupler (Figure C) connects to a ball that is
located on or under the rear bumper of tow vehicle. This
system of coupling a trailer to a tow vehicle is sometimes
referred to as “bumper pull.”
THE TOW VEHICLE, HITCH AND BALL MUST HAVE A
RATED TOWING CAPACITY EQUAL TO OR GREATER
THAN THE TRAILER Gross Vehicle Weight Rating
(GVWR). IT IS ESSENTIAL THAT THE HITCH BALL BE
OF THE SAME SIZE AS THE COUPLER.
A ball hitch trailer may be fitted with a tongue jack that can
raise and lower the coupler.The tongue jack is mounted to
the A-frame (front or tongue) part of the trailer. By rotating
the jack handle clockwise, the jack will extend and raise
the tongue of the trailer.
The ball size and load rating (capacity) are marked on the
ball. Hitch capacity is marked on the hitch.
WARNING
Coupler-to-hitch mismatch can result in uncoupling,
leading to death or serious injury.
Be sure the LOAD RATING of the hitch ball is equal or
greater than the load rating of the coupler.
Be sure the SIZE of the hitch ball matches the size of
the ball coupler.
Figure C. Ball Hitch Coupler
Before each tow, coat the ball with a thin layer of automotive
bearing grease to reduce wear and ensure proper operation.
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TRAILER GUIDELINES
Lower the trailer (Figure D) until the coupler fully engages
the hitch ball.
WARNING
A worn, cracked or corroded hitch ball can fail while
towing and may result in death or serious injury.
2-INCH
TRAILER
COUPLER
TOW
VEHICLE
Before coupling trailer, inspect the hitch ball for wear,
corrosion and cracks.
Replace worn or damaged hitch ball.
2-INCH
BALL
WARNING
Figure D. Ball Hitch Coupling Mechanism
A loose hitchball nut can result in uncoupling, leading
to death or serious injury.
Engage the coupler locking mechanism. In the engaged
position, the locking mechanism securely holds the
coupler to the hitch ball.
Be sure the hitch ball is tight to the hitch before coupling
the trailer.
Insert a pin or lock through the hole in the locking
mechanism.
Rock the ball to make sure it is tightened to the hitch,
and visually check that the hitch ball nut is solid against
the lock washer and hitch frame.
Be sure the coupler is all the way on the hitch ball and
the locking mechanism is engaged. A properly engaged
locking mechanism will allow the coupler to raise the rear
of the tow vehicle. Using the trailer jackstand, verify that
you can raise the rear of the tow vehicle by 1 inch after
the coupler is locked to the hitch.
Wipe the inside and outside of the coupler. Clean and
visually inspect it for cracks and deformations. Feel the
inside of the coupler for worn spots and pits.
Be sure the coupler is secured tightly to the tongue of the
trailer. All coupler fasteners must be visibly solid against
the trailer frame.
Lower the trailer so that its entire tongue weight is held
by the hitch.
The bottom surface of the coupler must be above the top
of the hitch ball. Use the tongue jackstand to support
the trailer tongue. Wood or concrete blocks may also
be used.
Raise the jackstand to a height where it will not interfere
with the road.
NOTICE
Coupling theTrailer to theTow Vehicle (Ball Coupler)
Overloading can damage the tongue jack. DO NOT
use the tongue jack to raise the tow vehicle more than
one inch.
Lubricate the hitch ball and the inside of the coupler with
a thin layer of automotive bearing grease.
If the coupler cannot be secured to the hitch ball, do not
tow the trailer. Call your dealer for assistance. Lower the
trailer so that its entire tongue weight is held by the hitch and
continue retracting the jack to its fully retracted position.
Slowly back up the tow vehicle so that the hitch ball is
near or aligned under the coupler.
Using the jackstand at the front of trailer (tongue), turn
the jackstand crank handle to raise the trailer. If the ball
coupler does not line up with the hitch ball, adjust the
position of the tow vehicle.
Open the coupler locking mechanism.Ball couplers have
a locking mechanism with an internal moving piece and
an outside handle. In the open position, the coupler is
able to drop fully onto the hitch ball.
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TRAILER GUIDELINES
Backup Lights (place tow vehicle gear shift in reverse).
Attaching Safety Chain
Turn Signals (activate tow vehicle directional signal
lever).
Visually inspect the safety chains and hooks for wear or
damage. Replace worn or damaged safety chains and
hooks before towing.
WARNING
Attach the safety chains so that they:
Improper electrical connection between the tow vehicle
and the trailer will result in inoperable lights and electric
brakes, and can lead to collision.
• Cross underneath the coupler. See Figure E.
TOW
VEHICLE
Before each tow:
TRAILER
TONGUE
• Check that the taillights, brake lights and turn signals
work.
• Check that the electric brakes work by operating the
brake controller inside the tow vehicle.
SAFETY CHAIN
MASTER LINK
IMPORTANT!
CROSS BOTH
SAFETY CHAINS
Uncoupling the Ball Hitch
Figure E. Attaching Safety Chain (Ball Hitch)
Follow these steps to uncouple ball hitch from tow
vehicle:
• Loop around a frame member of the tow vehicle or holes
provided in the hitch system (DO NOT attach them to
an interchangeable part of the hitch assembly).
Block trailer tires to prevent the trailer from rolling, before
jacking the trailer up.
• Have enough slack to permit tight turns, but not be
close to the road surface, so if the trailer uncouples, the
safety chains can hold the tongue up above the road
Disconnect the electrical connector.
Disconnect the breakaway brake switch cable. Promptly
replace the pullpin in the switchbox.
.
WARNING
Before extending jackstand, make certain the ground
surface below the jackstand foot will support the tongue
load.
Improper rigging of the safety chains can result in
loss of control of the trailer and tow vehicle, leading
to death or serious injury, if the trailer uncouples from
the tow vehicle.
Rotate the jackstand handle (or crank) clockwise. This
will slowly extend the jack and transfer the weight of the
trailer tongue to the jack.
• Fasten chains to frame of tow vehicle.DO NOT fasten
chains to any part of the hitch unless the hitch has
holes or loops specifically for that purpose.
• Cross chains underneath hitch and coupler with
enough slack to permit turning and to hold tongue
up, if the trailer comes loose.
Connecting Trailer Lights
Connect the trailer lights to the tow vehicle’s electrical
system using the electric connectors at the front of the
trailer (tongue). Refer to the wiring diagram shown in the
trailer wiring diagram section of this manual.Before towing
the trailer check for the following:
Running lights (turn on tow vehicle headlights).
Brake Lights (step on tow vehicle brake pedal).
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TRAILER GUIDELINES
If you see or feel evidence of wear, such as flat spots,
deformations, pitting or corrosion, on the pintle hook or
coupler, immediately have your dealer inspect them to
determine the proper action to prevent possible failure of
the ball andcoupler system.All bent or broken coupler parts
must be replaced before towing the trailer.
PINTLE HITCH COUPLER
A pintle eye coupler (Figure F) connects to a pintle-hook
hitch that is located on or under the rear bumper of the tow
vehicle.This system of coupling a trailer to a tow vehicle is
sometimes referred to as a “lunette eye, tow ring or G.I.
hitch.”
THE TOW VEHICLE, PINTLE HITCH AND PINTLE
COUPLER MUST HAVE A RATED TOWING CAPACITY
EQUAL TO OR GREATER THAN THE TRAILER Gross
Vehicle Weight Rating (GVWR).
IT IS ESSENTIAL THAT THE PINTLE HITCH BE OF THE
SAME SIZE AS THE PINTLE COUPLER.
The coupler size and load rating (capacity) are marked on
the coupler. Hitch capacity is marked on the hitch.
WARNING
Figure F. Pintle Hitch Coupler
Coupler-to-hitch mismatch can result in uncoupling,
leading to death or serious injury.
A pintle hitch trailer may be fitted with a tongue jackstand
that can raise and lower the coupler. The tongue jack is
mounted to the A-frame (front or tongue) part of the trailer.
By rotating the jack handle clockwise, the jack will extend
and raise the tongue of the trailer.
Be sure the LOAD RATING of the pintle hitch hook is
equal or greater than the load rating of the pintle eye
coupler.
The load rating of the coupler and the necessary pintle
hitch size are listed on the trailer tongue.You must provide
a pintle hitch and pintle coupler for your tow vehicle, where
the load rating of the pintle hitch and pintle coupler is equal
to or greater than that of your trailer.
Be sure the SIZE of the pintle hitch hook matches the
size of the pintle eye coupler.
WARNING
A worn, cracked or corroded pintle hitch hook can fail
while towing, and may result in death or serious injury.
Also, the pintle hitch size must be the same as the pintle
coupler size. If the hitch is too small, too large, underrated,
loose or worn, the trailer can come loose from the tow
vehicle, and may cause death or serious injury.
Before coupling trailer, inspect the pintle hitch hook for
wear, corrosion and cracks.
Replace worn or damaged pintle hitch hook.
Pintle Coupler and Pintle Hook
Before each tow, check the locking device that secures the
coupler to the pintle hook assembly.
Rock the pintle eye coupler to make sure it is secured
tightly to the hitch.
The pintle hook lever must be able to operate freely and
automatically snap into place into the latched position.
Lightly oil the pivot points and sliding surfaces with SAE30W
motor oil to prevent rust and help ensure proper operation
of the latching mechanism.
Wipe the inside and outside of the pintle coupler. Clean
and inspect it visually for cracks and deformations. Feel
the inside of the coupler for worn spots and pits.
Be sure the coupler is secured tightly to the tongue of the
trailer. All coupler fasteners must be visibly solid against
the trailer frame.
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TRAILER GUIDELINES
Raise the bottom surface of the coupler to be above the
top of the pintle hitch hook. Use the tongue jackstand
to support the trailer tongue. Wood or concrete blocks
may also be used.
Lower the trailer so that its entire tongue weight is held
by the hitch.
Raise the jackstand to a height where it will not interfere
with the road.
WARNING
TIRE SAFETY
A defective pintle hitch not properly fastened can result
in uncoupling, leading to death or serious injury.
Unsafe Tires, Lug Nuts or Wheels
Trailer tires and wheels are more likely to fail than car tires
and wheels because they carry a heavier load. Therefore,
it is essential to inspect the trailer tires before each tow.
Be sure the pintle hook is securly tighten to the tow
vehicle before coupling the trailer.
Coupling Trailer to Tow Vehicle (Pintle Coupler)
If a tire has a bald spot, bulge, cuts, is showing any cords,
or is cracked, replace the tire before towing. If a tire has
uneven tread wear, take the trailer to a dealer service
center for diagnosis.
Slowly back up the tow vehicle so that the pintle
hitch hook is near or aligned under the pintle eye ring
coupler.
Using the jackstand at the front of trailer (tongue), turn
the jackstand crank handle to raise the trailer.If the pintle
eye coupler does not line up with the pintle hitch hook,
adjust the position of the tow vehicle.
Uneven tread wear can be caused by tire imbalance, axle
misalignment or incorrect inflation.
Tires with too little tread will not provide adequate tracking
on wet roadways and can result in loss of control, leading
to death or serious injury.
OPEN the pintle hook locking mechanism (Figure G).
Place the hook inside the eye coupler.CLOSE the pintle
hook mechanism.
Improper tire pressure causes an unstable trailer and
can result in a tire blowout and loss of control. Therefore,
before each tow you must also check the tire pressure.Tire
pressure must be checked when tires are cold.
TRAILER
TONGUE
PINTLE
HOOK
TOW
VEHICLE
Allow 3 hours cool-down after driving as much as 1 mile at
40 mph before checking tire pressure. Trailer tires will be
inflated to higher pressures than passenger vehicle tires.
SAFETY CH
MASTER L
Since trailer wheels and lug nuts (or bolts) are subjected
to greater side loads than automobile wheels, they are
more prone to loosen. Before each tow, check to make
sure they are tight.
PINTLE
RING “EYE”
SAFETY
CHAIN
IMPORTANT!
CROSS BOTH
The proper tightness (torque) for lug nuts is listed in the
lug nut tightening section of this manual. Use a torque
wrench to tighten the lug nuts. If you do not have a torque
Figure G. Attaching Safety Chain (Pintle Hitch)
Insert a pin or lock through the hole in the locking
mechanism.
Be sure the pintle hook is inserted completely through
the eye ring and the locking mechanism is engaged.
A properly engaged locking mechanism will allow the
coupler to raise the rear of the tow vehicle. Using the
trailer jack, test to see that you can raise the rear of the
tow vehicle by1-inch after the coupler is locked to the
hitch.
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TRAILER GUIDELINES
wrench, use a lug wrench (from your tow vehicle) and
tighten the nuts as much as you can. Then have a service
garage or trailer dealer tighten the lug nuts to the proper
torque.
This certification/VIN label will indicate the trailer’s Gross
Vehicle Weight Rating (GVWR). This is the most weight
the fully loaded trailer can weigh. It will also provide the
Gross Axle Weight Rating (GAWR). This is the most a the
axle can weigh.
WARNING
There is a vehicle placard (Figure H) located in the same
location as the certification label described above. This
placard provides tire and loading information. In addition,
this placard will show a statement regarding maximum
cargo capacity.
Metal creep between the wheel rim and lug nuts will
cause rim to loosen and could result in a wheel coming
off, leading to death or serious injury.
Tighten lug nuts before each tow.
TIRE AND LOADING INFORMATION
Lug nuts are also prone to loosen after first being
assembled. When driving a new trailer (or after wheels
have been remounted), check to make sure they are tight
after the first 10, 25 and 50 miles of driving and before
each tow thereafter.
The weight of cargo should never exceed XXX kg. Or XXX lbs.
TIRE
SIZE
COLD TIRE PRESSURE
SEE OWNER’S
MANUAL FOR
ADDITIONAL
INFORMATION
FRONT
REAR
SPARE
Failure to perform this check can result in a wheel parting
from the trailer and a crash, leading to death or serious
injury.
Figure H. Trailer Tire Placard
If additional work items (hoses, tools, clamps etc.) are
going to be added to the trailer, be sure they are distributed
evenly to prevent overloading front to back and side to side.
Heavy items should be placed low and as close to the axle
positions as reasonable.Too many items on one side may
overload a tire.
WARNING
Lug nuts are prone to loosen after initial installation,
which can lead to death or serious injury.
Check lug nuts for tightness on a new trailer or when
wheel(s) have been remounted after the first 10, 25
and 50 miles of driving.
Excessive loads and/or underinflation cause tire overloading
and, as a result, abnormal tire flexing occurs.This situation
can generate an excessive amount of heat within the tire.
Excessive heat may lead to tire failure.It is the air pressure
that enables a tire to support the load, so proper inflation
is critical. The proper air pressure may be found on the
certification/VIN label and/or on the Tire and Loading
Information placard. This value should never exceed the
maximum cold inflation pressure stamped on the tire.
WARNING
Improper lug nut torque can cause a wheel parting from
the trailer, leading to death or serious injury.
Be sure lug nuts are tight before each tow.
WARNING
Perform the following steps to determine the load limit of
your trailer.
Improper tire pressure can result in a blowout and loss
of control, which can lead to death or serious injury.
Be sure tires are inflated to pressure indicated on side
wall before towing trailer.
Step 1.
Locate the statement, “The weight of cargo should never
exceed XXX kg or XXX lbs.,” on your vehicle’s Tire and
Loading Information placard (Figure I). This value equals
the available amount of equipment load capacity.
Determining Load Limit of Trailer
Determining the load limits of a trailer includes more than
understanding the load limits of the tires alone. On all
trailers there is a Federal certification/VIN label that is
located on the forward half of the left (road) side of the unit.
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TRAILER GUIDELINES
along with other care and maintenance activities, can
also:
Step 2.
Determine the weight of the equipment being loaded
on the tow vehicle. That weight may not safely exceed
the available equipment load capacity. The trailer’s Tire
Information Placard is attached adjacent to or near the
trailer’sVIN (Certification) label at the left front of the trailer
(See Figure I).
Improve vehicle handling.
Help protect you and others from avoidable breakdowns
and accidents.
Improve fuel economy.
Increase the tire life.
Determining Load Limit of Tow Vehicle
Use the information contained in this section to make tire
safety a regular part of your vehicle maintenance routine.
Recognize that the time you spend is minimal compared
with the inconvenience and safety consequences of a flat
tire or other tire failure.
Step 1.
Locate the statement, “The combined weight of occupants
and cargo should never exceed XXX lbs.,”on your vehicle’s
placard.
TIRE FUNDAMENTALS
Step 2.
Determine the combined weight of the driver and
passengers who will be riding in your vehicle.
Federallawrequirestiremanufacturerstoplacestandardized
information on the sidewall of all tires (Figure I). This
information identifies and describes the fundamental
characteristics of the tire and also provides a tire
identification number for safety standard certification and
in case of a recall.
Step 3.
Subtract the combined weight of the driver and passengers
from XXX kilograms or XXX pounds.
Step 4.
The resulting figure equals the available amount of cargo
and luggage capacity. For example, if the “XXX” amount
equals 1400 lbs. and there will be five 150 lb. passengers
in your vehicle, the amount of available cargo and luggage
capacity is 650 lbs. (1400-750 (5 x 150) = 650 lbs.).
Step 5.
Determine the combined weight of luggage and cargo
being loaded on the vehicle. That weight may not safely
exceed the available cargo and luggage capacity calculated
in Step 4.
Figure I. Standard Tire Sidewall Information
If your vehicle will be towing a trailer, load from your trailer
will be transferred to your vehicle.Consult the tow vehicle’s
manual to determine how this weight transfer reduces the
available cargo and luggage capacity of your vehicle.
P: The “P” indicates the tire is for passenger vehicles.
Next number: This three-digit number gives the width in
millimeters of the tire from sidewall edge to sidewall edge.
In general, the larger the number, the wider the tire.
Studies of tire safety show that maintaining proper tire
pressure, observing tire and vehicle load limits (not carrying
more weight in your vehicle than your tires or vehicle can
safely handle), avoiding road hazards and inspecting tires
for cuts, slashes and other irregularities are the most
important things you can do to avoid tire failure, such as
tread separation or blowout and flat tires. These actions,
Next number:This two-digit number, known as the aspect
ratio, gives the tire’s ratio of height to width. Numbers of
70 or lower indicate a short sidewall for improved steering
response and better overall handling on dry pavement.
P:The “R” stands for radial. Radial ply construction of tires
has been the industry standard for the past 20 years.
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TRAILER GUIDELINES
Next number: This two-digit number is the wheel or rim
diameter in inches. If you change your wheel size, you
will have to purchase new tires to match the new wheel
diameter.
in the tire. In general, the greater the number of plies, the
more weight a tire can support. Tire manufacturers also
must indicate the materials in the tire, which include steel,
nylon, polyester, and others.
Next number: This two- or three-digit number is the tire’s
load index. It is a measurement of how much weight each
tire can support. You may find this information in your
owner’s manual. If not, contact a local tire dealer. Note:
You may not find this information on all tires because it is
not required by law.
Maximum Load Rating: This number indicates the
maximum load in kilograms and pounds that can be carried
by the tire.
Maximum Permissible Inflation Pressure: This number
is the greatest amount of air pressure that should ever be
put in the tire under normal driving conditions.
M+S: The “M+S” or “M/S” indicates that the tire has
some mud and snow capability. Most radial tires have
these markings; hence, they have some mud and snow
capability.
Uniform Tire Quality Grading Standards (UTQGS)
Treadwear Number: This number indicates the tire’s
wear rate. The higher the treadwear number is, the longer
it should take for the tread to wear down. For example, a
tire graded 400 should last twice as long as a tire graded
200.
Speed Rating: The speed rating denotes the speed at
which a tire is designed to be driven for extended periods
of time.The ratings range from 99 miles per hour (mph) to
186 mph.These ratings are listed inTable A.Note:You may
not find this information on all tires because it is not required
by law.
Traction Letter: This letter indicates a tire’s ability to stop
on wet pavement. A higher graded tire should allow you
to stop your car on wet roads in a shorter distance than a
tire with a lower grade. Traction is graded from highest to
lowest as “AA”,”A”, “B”, and “C”.
Table A. Speed Rating
Letter Rating
Speed Rating
99 mph
Temperature Letter: This letter indicates a tire’s
resistance to heat. The temperature grade is for a tire that
is inflated properly and not overloaded. Excessive speed,
underinflation or excessive loading, either separately or
in combination, can cause heat build-up and possible tire
failure. From highest to lowest, a tire’s resistance to heat
is graded as “A”, “B”, or “C”.
Q
R
S
T
106 mph
112 mph
118 mph
U
H
V
W
Y
124 mph
130 mph
149 mph
Refer to Figure J for additional tire information for light
trucks.
168* mph
186* mph
U.S. DOTTire Identification Number:This begins with the
letters “DOT” and indicates that the tire meets all federal
standards. The next two numbers or letters are the plant
code where it was manufactured, and the last four numbers
represent the week and year the tire was built.For example,
the numbers 3197 means the 31st week of 1997.The other
numbers are marketing codes used at the manufacturer’s
discretion. This information is used to contact consumers
if a tire defect requires a recall.
Figure J. UTQGS Tire Information
Tire Ply Composition and Materials Used:The number of
plies indicates the number of layers of rubber-coated fabric
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TRAILER GUIDELINES
Tires for light trucks have other markings besides those
found on the sidewalls of passenger tires.
sidewall should not be repaired. Tires must be removed
from the rim to be properly inspected before being plugged
and patched.
LT: The “LT” indicates the tire is for light trucks or trailers.
ST: An “ST” is an indication the tire is for trailer use only.
Replacing Worn or Damaged Tires
Replace the tire before towing the trailer if the tire treads
have less than 1/16 inch depth or the telltale bands are
visible.Check inflation pressure weekly during use to insure
the maximum tire life and tread wear. A bubble, cut or bulge
in a side wall can result in a tire blowout. Inspect both side
walls of each tire for any bubble, cut or bulge; and replace
a damaged tire before towing the trailer.
Max. Load Dual kg (lbs) at kPa (psi) Cold:This information
indicates the maximum load and tire pressure when the tire
is used as a dual, that is, when four tires are put on each
rear axle (a total of six or more tires on the vehicle).
Max.Load Single kg (lbs) at kPa (psi) Cold:This information
indicates the maximum load and tire pressure when the tire
is used as a single.
Table B below will help pinpoint the causes and solutions
of tire wear problems.
Load Range: This information identifies the tire’s load-
carrying capabilities and its inflation limits.
Table B. Tire Wear Troubleshooting
Cause
Tire Safety Tips
Wear Pattern
Solution
Adjust pressure to particular
load per tire manufacturer.
Slow down if you have to go over a pothole or other
object in the road.
Center Wear Over inflation.
Edge Wear Under inflation.
Adjust pressure to particular
load per tire manufacturer.
DO NOT run over curbs or other foreign objects in the
roadway, and try not to strike the curb when parking.
Make sure load does not
exceed axle rating.
Align wheels.
Loss of camber
Side Wear
or overloading.
Check tire inflation pressure weekly during use to insure
the maximum tire life and tread wear.
Toe Wear
Cupping
Incorrect toe-in.
Out-of-balance.
Align wheels.
DO NOT bleed air from tires when they are hot.
Check bearing adjustment
and balance tires.
Inspect tires for uneven wear patterns on the tread,
cracks, foreign objects, or other signs of wear or
trauma.
Wheel lockup and Avoid sudden stops when
tire skidding. possible and adjust brakes.
Flat Spots
Remove bits of glass and foreign objects wedged in
the tread.
WARNING
Make sure your tire valves have valve caps.
ALWAYS wear safety glasses when
removing or installing force fitted parts.DO
NOT attempt to repair or modify a wheel.
DO NOT install an inner-tube to correct a
leak through through the rim. If the rim is
ALWAYS check tire pressure on tow vehicle and trailer
before towing. Check tire pressure at least once a
month.
DO NOT overload tow vehicle.Check the tire information
and loading placard for safe allowable tire loading
conditions.
cracked, the air pressure in the inner tube may cause
pieces of the rim to explode (break off) with great force
and cause serious eye or bodily injury.
Tire Repair
The proper repair of a punctured tire requires a plug for the
hole and a patch for the area inside the tire that surrounds
the puncture hole. Punctures through the tread can be
repaired if they are not too large, but punctures to the
PAGE 50 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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TRAILER GUIDELINES
3. Check to see if the lug nuts are tight after the first 10,
25 and 50 miles of driving and before each tow
thereafter
Wheel Rims
If the trailer has been struck, or impacted, on or near the
wheels, or if the trailer has struck a curb, inspect the rims for
damage (i.e.being out of round);and replace any damaged
wheel. Inspect the wheels for damage every year, even if
no obvious impact has occurred.
Wheels, Bearings and Lug Nuts
A loose, worn or damaged wheel bearing is the most
common cause of brakes that grab.
To check wheel bearings, jack trailer and check wheels
for side-to-side looseness. If the wheels are loose, or spin
with a wobble, the bearings must be serviced or replaced.
Check inflation pressure weekly during use to insure the
maximum tire life and tread wear. Most trailer axles are
built with sealed bearings that are not serviceable. Sealed
bearings must be replaced as complete units.
WARNING
Figure K. Wheel Lug Nuts Tightening Sequence
Lug nuts are prone to loosen after initial installation,
which can lead to death or serious injury. Check all
wheel lug nuts periodically.
Table C. Tire Torque Requirements
First Pass
FT-LBS
Second Pass
FT-LBS
Third Pass
FT-LBS
Wheel Size
Lug Nut Torque Requirements
12"
13"
14"
15"
16"
20-25
20-25
20-25
20-25
20-25
35-40
35-40
50-60
50-60
50-60
50-65
50-65
It is extremely important to apply and maintain proper wheel
mounting torque on the trailer. Be sure to use only the
fasteners matched to the cone angle of the wheel. Proper
procedure for attachment of the wheels is as follows:
90-120
90-120
90-120
1. Start all wheel lug nuts by hand.
2. Torque all lug nuts in sequence. See Figure K. DO
NOT torque the wheel lug nuts all the way down.
Tighten each lug nut in 3 separate passes as defined
by Table C.
Lights and Signals
Before each tow, check the trailer taillights, stoplights, turn
signals and any clearance lights for proper operation.
Replace any broken or burned-out lamps as necessary.
Check the wire harness for cuts, fraying or other damage.
If it needs replacing, contact your dealer.
NOTICE
NEVER use an pneumatic air gun to tighten wheel
lug nuts.
WARNING
Over-tightening lug nuts will result in breaking the studs
or permanently deforming the mounting stud holes in
the wheels.
Improper operating taillights, stoplights and turn signals
can cause collisions.
Check all lights before each tow.
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 51
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TRAILER WIRING DIGRAM
Figure 37. Trailer Wiring Diagram
PAGE 52 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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GENERATOR WIRING DIGRAM
Figure 38. Generator Wiring Diagram (DA7000 SERIES)
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 53
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ENGINE WIRING DIGRAM
Figure 39. Engine Wiring Diagram
PAGE 54 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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TROUBLESHOOTING (ENGINE AND GENERATOR)
Table 9. Engine and Generator Troubleshooting
SYMPTOM
POSSIBLE PROBLEM
Dead Battery?
SOLUTION
Replace Battery.
Replace Switch.
Replace Starter.
Replace Fuse.
Defective Starter Switch?
Defective Starter?
Engine fails to start and
starter does not rotate.
Fuse F5 Burned Out?
Broken Pre-Heat Circuit?`
No Fuel?
Check Pre-Heat Circuit.
Add Fuel.
Engine fails to start and
starter rotates.
Defective Wiring?
Check Wiring.
Defective Idle Control Switch?
Idle Control Switch is in ON position?
Clogged Fuel Strainer?
Clogged Air Cleaner?
Replace Switch.
Set Switch to OFF Position.
Clean or Replace.
Engine starts "Idle
Control Switch" is
in OFF position and
engine remains at low
speed.
Clean or Replace.
Defective Idle Control Device?
Disconnected Wiring?
Replace.
Check and Repair Wiring.
Replace Rectifier (RE1).
Replace Rotor.
No Voltage Present in AC Power source
Defective Rotor?
Engine starts and "Idle
Control Switch" is in
OFF position. Engine
speed rises and no
voltage is present in AC
power source.
Defective Voltmeter?
Replace Voltmeter.
Check and Repair Wiring.
Replace Armature.
Replace Circuit Breaker (Protector).
Disconnected Wiring?
Layer Short-Circuit in armature winding?
Engine starts and "Idle Defective Circuit Breaker (Protector)?
Control Switch" is in
OFF position . Engine
Layer Short-Circuit, Broken Wires In
Armature Winding?
speed rises and AC
power voltage is too low
or cannot be used.
Repair or Replace Armature.
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 55
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TROUBLESHOOTING (ENGINE AND GENERATOR)
Table 9. Engine and Generator Troubleshooting (Continued)
SYMPTOM
POSSIBLE PROBLEM
SOLUTION
Replace Regulator.
Engine starts and "Idle Defective Engine Regulator?
Control Switch" is in
OFF position. Engine
speed rises and battery
discharges too soon.
Defective Wiring?
Repair or Replace Wiring.
Repair or Replace Alternator.
Replace Alternator Bearings.
Engine starts and "Idle Defective Alternator?
Control Switch" is in
OFF position. Engine
speed rises and engine
seems overloaded.
Damaged Alternator Bearing?
Engine starts and "Idle
Control Switch" is in
OFF position. Engine
Bad Engine Installation?
speed rises and engine
Repeat Installation of of Engine.
has large vibrations.
overload.
Engine starts and "Idle Loose Engine Parts?
Control Switch" is in
Check All Engine Parts For Tightnes.
Check Alternator for Damaged Bearing or
Loose Clamping Bolts.
Defective Alternator?
OFF position. Engine
speed rises and engine
has abnormal noise.
Defective Enclosure?
Check Enclosure Bolts for Tightness.
Engine starts and "Idle Defective Idle Control Device?
Control Switch" is in OFF
Repair or Replace Idle Control Device.
Replace Idle Control Switch.
Replace Solenoid.
Defective Idle Control Switch?
position. Engine speed
rises and remains at high
Defective Solenoid?
speed when Idle Control
switch is placed in the ON
position.
Defective Relay?
Replace Relay.
PAGE 56 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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TROUBLESHOOTING (ENGINE)
Table 10. Engine Troubleshooting
POSSIBLE PROBLEM
No fuel?
SYMPTOM
SOLUTION
Replenish fuel.
Air in the fuel system?
Water in the fuel system?
Fuel pipe clogged?
Bleed system.
Remove water from fuel tank.
Clean fuel pipe.
Fuel filter clogged?
Clean or change fuel filter.
Excessively high viscosity of fuel or
engine oil at low temperature?
Use the specified fuel or engine oil.
Use the specified fuel.
Tighten nut.
Fuel with low cetane number?
Fuel leak due to loose injection pipe
retaining nut?
Engine does not start.
Incorrect injection timing?
Fuel cam shaft worn?
Adjust.
Replace.
Injection nozzle clogged?
Injection pump malfunctioning?
Clean injection nozzle.
Repair or replace.
Seizure of crankshaft, camshaft, piston,
cylinder liner or bearing?
Repair or replace.
Replace head gasket, tighten cylinder
head bolt, glow plug and nozzle holder.
Compression leak from cylinder?
Improper valve timing?
Piston ring and liner worn?
Excessive valve clearance?
Battery discharged?
Correct or replace timing gear.
Replace.
Adjust.
Charge battery.
Repair or replace.
Repair or replace.
Connect wiring.
Starter malfunctioning?
Key switch malfunctioning?
Wiring disconnected?
Starter does not run.
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 57
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TROUBLESHOOTING (ENGINE)
Table 10. Engine Troubleshooting (Continued)
POSSIBLE PROBLEM
Fuel filter clogged or dirty?
SYMPTOM
SOLUTION
Clean or change.
Air cleaner clogged?
Clean or change.
Tighten nut.
Fuel leak due to loose injection pipe retaining
nut?
Engine revolution is not
smooth
Injection pump malfunctioning?
Incorrect nozzle opening pressure?
Injection nozzle stuck or clogged?
Fuel over flow pipe clogged?
Governor malfunctioning?
Excessive engine oil?
Repair or replace.
Adjust.
Repair or replace.
Clean.
Repair.
Reduce to the specified level.
Repair or replace.
Adjust.
Either white or
blue exhaust gas is
observed.
Piston ring and liner worn or stuck?
Incorrect injection timing?
Deficient compression?
Overload?
Adjust top clearance.
Lessen the load.
Use the specified fuel.
Clean or change.
Clean or change.
Repair or replace the nozzle.
Adjust.
Low grade fuel used?
Either black or dark
gray exhaust gas is
observed.
Fuel filter clogged?
Air cleaner clogged?
Deficient nozzle injection?
Incorrect injection timing?
Engine's moving parts seem to be seizing? Repair or replace.
Uneven fuel injection?
Repair or replace the injection pump.
Deficient output.
Deficient nozzle injection?
Repair or replace the nozzle.
Replace head gasket, tighten cylinder head
bolt, glow plug and nozzle holder.
Compression leak?
PAGE 58 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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NOTES
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 59
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EXPLANATION OF CODE IN REMARKS COLUMN
The following section explains the different symbols and
QTY. Column
remarks used in the Parts section of this manual. Use the
help numbers found on the back page of the manual if there
are any questions.
Numbers Used — Item quantity can be indicated by a
number, a blank entry, or A/R.
A/R (As Required) is generally used for hoses or other
parts that are sold in bulk and cut to length.
NOTICE
The contents and part numbers listed in the parts
section are subject to change without notice.Multiquip
does not guarantee the availability of the parts listed.
A blank entry generally indicates that the item is not sold
separately.Other entries will be clarified in the “Remarks”
Column.
SAMPLE PARTS LIST
REMARKS Column
NO. PART NO. PART NAME
QTY. REMARKS
Some of the most common notes found in the “Remarks”
Column are listed below. Other additional notes needed
to describe the item can also be shown.
1
2%
12345
BOLT .....................1 .....INCLUDES ITEMS W/%
WASHER, 1/4 IN. ..........NOT SOLD SEPARATELY
WASHER, 3/8 IN. ..1 .....MQ-45T ONLY
2% 12347
3
4
12348
12349
HOSE ..................A/R ...MAKE LOCALLY
BEARING ..............1 .....S/N 2345B AND ABOVE
Assembly/Kit — All items on the parts list with the
same unique symbol will be included when this item is
purchased.
NO. Column
Indicated by:
Unique Symbols — All items with same unique
symbol
“INCLUDES ITEMS W/(unique symbol)”
(@, #, +, %, or >) in the number column belong to the
same assembly or kit, which is indicated by a note in the
“Remarks” column.
Serial Number Break — Used to list an effective serial
number range where a particular part is used.
Indicated by:
Duplicate Item Numbers — Duplicate numbers indicate
multiple part numbers, which are in effect for the same
general item, such as different size saw blade guards in
use or a part that has been updated on newer versions
of the same machine.
“S/N XXXXX AND BELOW”
“S/N XXXX AND ABOVE”
“S/N XXXX TO S/N XXX”
Specific Model Number Use — Indicates that the part
is used only with the specific model number or model
number variant listed. It can also be used to show a
part is NOT used on a specific model or model number
variant.
NOTICE
When ordering a part that has more than one item
number listed, check the remarks column for help in
determining the proper part to order.
Indicated by:
“XXXXX ONLY”
“NOT USED ON XXXX”
PART NO. Column
Numbers Used — Part numbers can be indicated by a
number, a blank entry, or TBD.
“Make/Obtain Locally” — Indicates that the part can
be purchased at any hardware shop or made out of
available items.Examples include battery cables, shims,
and certain washers and nuts.
TBD (To Be Determined) is generally used to show a
part that has not been assigned a formal part number
at the time of publication.
“Not Sold Separately”— Indicates that an item cannot
be purchased as a separate item and is either part of an
assembly/kit that can be purchased, or is not available
for sale through Multiquip.
A blank entry generally indicates that the item is not sold
separately or is not sold by Multiquip. Other entries will
be clarified in the “Remarks” Column.
PAGE 60 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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SUGGESTED SPARE PARTS
DA7000 SERIES GENERATORS WITH KUBOTA
Z482-EB/Z482-E2B/ Z482-E3B DIESEL ENGINES
NOTICE
Part numbers on this Suggested Spare Parts list may
supersede/replace the part numbers shown in the
following parts lists.
1 to 3 units
Qty.
5............1556211010..........AIR FILTER
P/N
Description
5............7000011221..........AIR FILTER, ELEMENT
5............1523143560..........FUEL FILTER
5............7000015241..........OIL FILTER CARTRIDGE, Z482-EB/Z482-E2B ENGINES
5............1585332435..........OIL FILTER, CARTRIDGE, Z482-E3B ENGINE
2............1980572531..........FAN BELT
1............3741059110..........STARTER SWITCH
5............3741055150..........IGNITION KEY
1............1584139010..........OIL SENDING UNIT, Z482-EB ENGINE
1............1584139013..........OIL SENDING UNIT, Z482-E2B/Z482-E3B ENGINES
1............D2312500103.......RADIATOR HOSE (UPPER)
1............D2312500003.......RADIATOR HOSE (LOWER)
1............0810105800..........FUEL CAP
1............0601842463..........RESISTOR
1............0602201378..........REGULATOR
1............0601807456..........CIRCUIT BREAKER
1............0601827350..........CONTROL UNIT
2............0601810830..........BULB, INDICATOR ASSY.
3............0601806640..........FUSE, 65 AMP
4............1685165510..........GLOW PLUG, Z482-EB ENGINE
4............1685165512..........GLOW PLUG, Z482-E2B/Z482-E3B ENGINES
2............1554383040..........SWITCH, WATER TEMP., Z482-EB ENGINE
2............1753883040..........SWITCH, WATER TEMP., Z482-E2B/Z482-E3B ENGINES
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 61
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NAMEPLATE AND DECALS ASSY.
OPERATING PROCEDURE
MULTIQUIP WhisperWatt
AC Generator
CHECK DAILY
CAUTION
17
1. Check the oil level.
9. Let the engine idle for more than
5
minutes
26
1. Maintain water/coolant level
at top of radiator coils.
2. Check the water level.
with the Idle Control switch in “ON” position.
10. Check the engine for abnormal vibrations noise
and oil leakage.
3. Check the fuel level.
4. Turn the Idle Control switch to “ON”.
5. Insert the key into the Starter Switch.
6. Turn the key to “RUN”. The Charge
Warning lamp and the Oil Pressure Warning lamp
should be lit.
11. Turn the Idle Control switch to either “ON” or
“OFF” for full engine operation.
WATER
COOLANT
LEVEL
2. Maintain reserve tank water/
coolant level between H and
12. After generating let the engine run for
5
minutes
with the Idle Control switch in the “ON” position.
NEVER STOP THE ENGINE SUDDENLY EXCEPT
IN AN EMERGENCY.
23
7. Turn the key to “HEAT”. When the preheat lamp
lights turn the key to “START” to start the engine.
AVOID HIGH SPEEDS IMMEDIATELY AFTER
STARTING.
FUSE PULLY
L
50/50 Anti-Freeze/Water.
mark. Use mixture of
a
10
13. Stop the engine by turning the key in the
Starter Switch to “STOP” and remove the key.
F6
F5
F4
F3
F2
F1
8. When the engine starts, the Oil Pressure
Alarm lamp should go out.
A555000103
3. Add coolant when reserve
tank is low (L). Fill to the H
mark with Anti-Freeze/Water.
15A
5A
WARNING!
Before connecting this generator to any building’s
electrical system, licensed electrician must install
an isolation [transfer] switch.
H
L
RESERVE
TANK
a
5A
DCL194
Serious injury or death may result without this
transfer switch.
5A
30A
16
WHISPERW
AT
T
25A
25A
30
13
20A
25A
7KW
AC
Model
DA-7000SS
120V
120V/240V
ON
RU
N
ST
OP
HEA
T
AC POWER OUTPUT
OFF
TRO
A55200000A
IDLE
CON
AC
L
VOL
TMETER
33
AC
CIRCUIT
BREAKER
ST
AR
T
00
HO
0
0
0
7000
W
DIESEL
AT
T
UR
S
POWERED
ST
AR
TER
SWITCH
HO
UR
AC
GENERA
TO
METE
R
R
DANGER
THE POSSIBILITY EXISTS OF ELECTROCUTION IF
GENERATOR/WELDER IS NOT PROPERLY GROUNDED.
ALWAYS CONNECT EARTH GROUND (GROUND
ROD) TO GENERATOR G.F.C.I. GROUND TERMINAL.
34
22
FUEL COCK
ON
GROUND
GE
G
CABLE
#8 MINIMUM
NE
RO RA
UN TO
D
R
LUG
G.F.C.I
GROUND
STUD
GROUND ROD
FOR EARTH
GROUND
5
G.F
.C.I.
ON
CONNECT TO
D9
22
00
10
0
BUILDING
GROUND
(OPTION)
G.F
.C.I.
92
20
01
00
D
GROUND
for
G.F
.C.I
FOR FURTHER GROUNDING
27
INSTRUCTIONS, READ MANUAL
8
FT. MINIMUM
REFERENCE
S
-3
82
NEC 250-52(C)
1
8
D93110000
OIL LEVEL
DIPSTICK
CAUTION
22
Before starting the engine, check that the oil
level is within the indicated operating range.
If the level is above the mark or below
H
L
0
9
9
0
2
-
S
25
H
DANGER
Using a generator indoors CAN KILL YOU IN MINUTES.
the L mark, it is important to correct before
operating to avoid damage to the engine.
DANGER
touch
Do
internal
not
1
9
0
2
-
output
S-
49
85
S
ELECTRICAL
SHOCK
HAZARD
wiring
terminals
while
nit
T
urn
of
f
or
u
power
is
before
o
perating.
servicing.
personnel
Only
install,
use
equipment.
Generator exhaust contains carbon monoxide. This is
a posion you cannot see or smell
qualified
or
service
should
this
4
0
1
4
DRAIN
-1
S
O.
N
MODEL
SERIAL
COOLANT
20A
120
2900
V
G-29R
120V
A
B
C
C
I
R
K
C
U
20A
120
20A
120
2900
V
2900
V
GA-2.9R
GA-2.9R
ON
15
120V
A
B
C
C
I
R
C
U
I
120V
A
B
R
C
C
I
R
K
C
U
I
OFF
G
ON
ON
ROUND
OFF
OFF
3
0
4
3
-1
S
Only use OUTSIDE and
far away from windows,
doors, and vents.
NEVER use inside a home
or garage, even if doors
and windows are open
DRAIN
S
-1
1
2
3
OIL
R
O
N
CAUTION
E
A
T
N
C
LA
M
O
Avoid other generator hazards.
READ MANUAL BEFORE USE.
LE
E
U
S
R
C
P
E
36
E
H
E
L
6
0
4
FUEL
R
1
-
R
S
E
P
R
100
Y
PA
V
DRAIN
E
E
2
S-3060
11
4
35
DANGER EXPLOSIVE GASES
Cigarettes, flames or sparks could cause battery to explode. Always
shield eyes and face from battery. Do not charge or use booster cables
or adjust post connections without proper instruction and training.
KEEP VENT CAPS TIGHT AND LEVEL
24
FRONT VIEW
POISON CAUSES SEVERE BURNS
Contains sulfuric acid. Avoid contact with skin, eyes or clothing. In
event of accident flush with water and call
a
physician immediately.
KEEP OUT OF REACH OF CHILDREN
WARNING
Only operate machine in well ventilated
areas.
DO NOT inhale exhaust gases.
S-4984
Only qualified personnel should
install, use or service this
equipment.
6
DANGEROUS
GAS
14
COOLING
12
20
WATER
S-3061
WARNING
MOVING PARTS can cause
severe injury.
DO NOT operate with
doors open.
USE #2 DIESEL
FUEL ONLY
S-1408
19
Stop engine before
servicing.
DCL182
CAUTION
HOT PARTS can burn skin.
WARNING
HOT COOLANT can cause
severe burns.
18
DO NOT touch until the
machine has sufficiently
cooled.
DO NOT remove cap if
radiator is hot.
DCL181
DCL183
29
28
TM
7000
TT
A
W
32
WHISPER
37
31
DECAL
KIT
8
0
4
-1
S
1
6
0
Y
3
-
S
DIESEL
R
E
ONL
#2
T
7
W
A
USEFUEL OCK
O
COOLING
ON
CAUTION
NOT
WITH
DO
TE
S-1409
OPEN
OPERA
DOORS
REAR VIEW
PAGE 62 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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NAMEPLATE AND DECALS ASSY.
NO.
1
2#
3#
4#
5#
6#
6#
PART NO.
PART NAME
QTY.
REMARKS
0800628504
1630645004
1630647004
1630610404
1630680104
1630680004
B9504501204
1630610504
0600689404
0800689504
6390671104
7810680104
7810680204
8700611603
8700611804
8700611904
A5552000003
A5552000013
A5552000103
A5552000113
B9504000304
B9504000404
B9504100104
B9504500004
7670624004
D9522001004
0820610404
0820650604
8700611524
B9505000304
8700625504
A556200004
A5562100003
A5562100104
A5562100204
A5562100303
A5562100404
A5562100504
D9531100004
A9504000014
DECAL: GROUND .............................................1................S1123
DECAL: OIL DRAIN...........................................1................S1403
DECAL: COOLANT DRAIN................................1................S1404
DECAL: CAUTION (PAPER ELEMENT)............1................S1406
DECAL: FUEL COCK.........................................1................S1407
DECAL: USE 2 DIESEL FUEL ONLY ................1................S1408
DECAL: DIESEL FUEL .....................................1................B90450120 — DA7000SSA
DECAL: CAUTION (DOORS OPEN) .................2................S1409
DECAL: BATTERY POSITIVE ...........................1................S2090
DECAL: BATTERY NEGATIVE ..........................1................S2091
DECAL: IMPORTANT CHECK DAILY................1................S2377
DECAL: FUEL DRAIN........................................1................S3060
DECAL: COOLING WATER ...............................1................S3061
DECAL: GROUND FOR G. F. C. I. .....................1................S3821REPLACESP/N7670624004
DECAL: WARNING DANGEROUS GAS ...........1................S4984
DECAL: DANGER ELECT. SHOCK HAZ...........1................S4985
DECAL: AC POWER OUTPUT..........................1................A55200000
DECAL: AC POWER OUTPUT..........................1................A55200001 — DA7000SSA
DECAL: OPERATING PROCEDURE ................1................A55200010
DECAL: OPERATING PROCEDURE ................1................A55200011 — DA7000SSA
DECAL: CAUTION HOT PARTS ........................1................B90400030
DECAL: WARNING MOVING PARTS ................2................B90400040
DECAL: WARNING HOT COOLANT .................1................B90410010
DECAL: WARNING DIESEL FUEL....................1................B90450000
DECAL: G. F. C. I...............................................2................D92200100
DECAL: G. F. C. I...............................................2................D92200100 — DA7000SSA
DECAL: WARNING (TRANSFER SWITCH)
DECAL: DANGER EXPLO GASES (BATT.)
DECAL: CAUTION OIL LEVEL GAUGE
DECAL: CAUTION OIL LEVEL GAUGE ............1................B90500030 — DA7000SSA
DECAL: FUSE BOX
DECAL: MQ .......................................................1................A56200000
DECAL: STRIPE MULTIQUIP............................1................A56210000
DECAL: STRIPE MQ .........................................1................A56210010
DECAL: STRIPE MQ .........................................1................A56210020
DECAL: STRIPE WHISPERWATT.....................2................A56210030
DECAL: STRIPE................................................1................A56210040
DECAL: STRIPE................................................1................A56210050
DECAL: DANGER GROUNDING.......................1................D93110000
DECAL: DANGER HAZARDOUS FUMES.........1................A90400001
PLATE, SERIAL NO...........................................1................CONTACT MQ PARTS DEPT.
............................................................................ ...............WITH MODEL AND S/N
KIT, DECAL........................................................1................INCLUDES ITEMS W/#
7#
8#
9#
10#
11#
12#
13#
14#
15#
16#
16#
17#
17#
18#
19#
20#
21#
22#
22#
23#
24#
25#
25#
26#
27#
28#
29#
30#
31#
32#
33#
34
1
1
1
1
35
36
37
DCLDA7000SS
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 63
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GENERATOR ASSY.
PAGE 64 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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GENERATOR ASSY.
NO.
1
PART NO.
A5110100003
PART NAME
ROTOR ASSY. ...................................................1................INCLUDES ITEMS W/#
QTY.
REMARKS
1-1# A5116000103
1-2# 7871025004
1-3# 042006304
1-4# A5113100002
1-5# 0171707033
1-6# 1991072004
1-7# 0012308020
FIELD ASSY.
RECTIFIER ASSY.
1
2
BEARING 6304 DOU.........................................1................REPLACES 0071206304
FAN
KEY
SET WASHER FAN
HEX HEAD BOLT
1
1
1
1
2
3
4
011208025
A515510002
A5136000103
HEX HEAD BOLT...............................................5................REPLACES 0012308025
END BRACKET
ARMATURE ASSY.
1
1
5
A6155000002C END BRACKET .................................................1................REPLACES A6155000002
6
7
8
9
7871329514
7901316004
0040008000
031108160
GROMMET
SET BOLT
WASHER, LOCK
1
4
4
WASHER, FLAT.................................................4................REPLACES 0041206000
10
11
11
12
13
14
14A
A6155400104C COVER ..............................................................1................REPLACES A6155400104
0027106012
0027105012
0012308020
0805084704
020108060
0801086104
MACHINE SCREW
MACHINE SCREW............................................3................DA7000SSA
3
HEX HEAD BOLT
RUBBER SUSPENSION
6
2
HEX NUT ...........................................................2................REPLACES 0207006000
WASHER, FLAT
2
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 65
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CONTROL PANEL ASSY.
PAGE 66 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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CONTROL PANEL ASSY.
NO.
1
1
2
3
4
5
6
7
PART NO.
PART NAME
CONTROL PANEL
QTY.
REMARKS
A5225000303
A5511302402
0021805020
0601800258
0207003000
0601807456
4341817004
0021004016
0601830771
1628663602
3741055150
0601810523
0601810830
0601800682
0027403512
0030003500
0601811034
0601812529
0601811031
0601812597
0021004010
0030004000
0601806420
0027103005
0601815109
1
CONTROL PANEL.............................................1................DA7000SSA
MACHINE SCREW
AC VOLTMETER, 120/240
HEX NUT
CIRCUIT BREAKER, KM52 265V 25A
BRACKET CIRCUIT BREAKER
MACHINE SCREW
IDLE CONTROL SWITCH
STARTER SWITCH ...........................................1................REPLACES 0602100077
IGNITION, KEY
INDICATOR ASSY.
BULB
HOUR METER 820114
MACHINE SCREW
HEX NUT
RECEPTACLE CS6369 125 250V 50A..............1................REPLACES 0601812566
RECEPTACLE, L14- 30R 125V 30A
RECEPTACLE, L5-30R 125V 30A.....................1................REPLACES 0601811035
RECEPTACLE, 5-20R 120V 20A......................1................REPLACES 0601812598
4
1
2
1
1
2
1
8
9
9A
10
10A
11
12
12A
13
14
15
16
17
17A
18
19
20
1
4
1
2
2
1
MACHINE SCREW
HEX NUT ...........................................................8................REPLACES 0207004000
CIRCUIT PROTECTOR, AC 250V 20A
MACHINE SCREW
GROUND TERMINAL
8
1
2
1
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 67
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ELECTRIC PARTS ASSY.
PAGE 68 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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ELECTRIC PARTS ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
PART NAME
QTY.
REMARKS
A5262500203
0016906016
0601842463
0027104012
0601823204
0027103020
0601823754
0027105016
1569465990
0017105016
1747260604
0017105025
0601815731
0601815759
0027105020
8701899004
0601806642
0601806643
BRACKET ELECTRIC PARTS
HEX HEAD BOLT
RESISTOR, 30W 10 OHM
MACHINE SCREW
RECTIFIER, S5VB60
MACHINE SCREW
RELAY
1
4
1
2
2
2
1
1
MACHINE SCREW
9
LAMP TIMER.....................................................1................REPLACES 0602201273
HEX HEAD BOLT
EMERGENCY UNIT ..........................................1................REPLACES 0602200475
HEX HEAD BOLT
TERMINAL BOARD
TERMINAL BOARD
MACHINE SCREW
FUSE BOX
FUSE, 5A
FUSE, 15A
FUSE, 30A
MACHINE SCREW
CONTROL UNIT
MACHINE SCREW
REGULATOR.....................................................1................REPLACES 1584464601
HEX HEAD BOLT
ROTARY SOLENOID .........................................1................REPLACES 1620150404
ARM SOLENOID
SPRING PIN
HEX HEAD BOLT...............................................1................REPLACES 0010106025
HEX NUT ...........................................................1................REPLACES 0030006000
HEX NUT
GOVERNOR ROD
10
11
12
13
14
15
16
16A
16B
1
4
1
1
4
1
4
2
2
2
1
2
16C 0601806644
17
18
19
20
21
22
23
24
25
25A
26
27
28
29
30
31
32
33A
33
34
35
0027105020
0601827350
0027104010
1584464600
0017105025
16226361032
1992636004
0050403020
16226361032
0030006000
0207206000
D235630004
031108160
0605010503
0042806000
505015300
0010108050
020108060
0601806640
A5485500004
0016906016
2
1
1
2
1
WASHER, FLAT.................................................1................REPLACES 0041608000
SNAP PIN
WASHER, FLAT
SNAP PIN ..........................................................1................REPLACES 0605010502
HEX HEAD BOLT
HEX NUT ...........................................................1................REPLACES 0207008000
FUSE, 65A
GUIDE
HEX HEAD BOLT
1
1
1
1
1
2
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 69
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ENGINE AND RADIATOR ASSY.
PAGE 70 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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ENGINE AND RADIATOR ASSY.
NO.
1
1
PART NO.
PART NAME
QTY. REMARKS
A5925200004 ENGINE, Z482EB ........................1........DA7000SS
A5924200004 ENGINE, Z482E2BDGDE2..........1........DA7000SS
A5924200094 ENGINE, Z482E3BDGDE2..........1........DA7000SSA
1
1A
1-1
1-1
2
3
4
5
6
6
1980572531
7000015241
1585332435
8745112003
0012410020
7085419004
0207010000
0602012750
0602012795
FAN BELT.....................................1........REPLACES P/N 0602011477
CARTRIDGE OIL FILTER ............1........REPLACES P/N's 1584132430 AND 0602041271
CARTRIDGE OIL FILTER ............1........Z482-E3B ENGINE
ENGINE FOOT
HEX HEAD BOLT
RUBBER SUSPENSION
HEX NUT
2
8
2
2
RADIATOR ...................................1........INCLUDES ITEM W/#
RADIATOR ...................................1........INCLUDES ITEM W/% DA7000SSA
6-1# 0602011074
6-1% 0602011079
CAP RADIATOR
CAP RADIATOR...........................1........DA7000SSA
1
7
8
9
8702014004
0605000460
D2312500103 RADIATOR HOSE
D2312500003 RADIATOR HOSE
INSULATOR .................................2........DA7000SS-DA7000SSW ONLY
RUBBER MOUNT
2
1
1
2
10
11
11
12
13
13A
14
14A
15
16
17
18
19
20
21
22
23
24
25
0605515111
0605515134
0605515003
1556211010
7000011221
3415013960
0222600340
0016908030
0207008000
8742031004
0016908020
0016906016
8742032003
1612036203
0605515006
0605515021
1622014103
1502025103
HOSE BAND, Ø34
HOSE BAND HS-16.....................2........DA7000SSA
HOSE BAND, Ø30
FILTER AIR CLEANER ASSY. .....1........REPLACES P/N 0602046265
2
ELEMENT AIR CLEANER ...........1........REPLACES P/N's 0602046374, 1556211081
BAND
1
1
1
1
1
2
2
1
1
1
2
1
1
RUBBER CUSHION
HEX HEAD BOLT
HEX NUT
BRACKET AIR CLEANER
HEX HEAD BOLT
HEX HEAD BOLT
HOSE AIR CLEANER
HOSE AIR CLEANER
HOSE BAND, Ø50
HOSE BAND, Ø55
DRAIN JOINT WATER
DRAIN JOINT OIL
NOTICE
For Tier II white units air cleaner assy., See Kubota
engine section in this manual.
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 71
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ENGINE AND RADIATOR ASSY.
PAGE 72 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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ENGINE AND RADIATOR ASSY.
NO.
26
27
28
29
30
31
31
32
33
34
35
36
37
38
38
39
40
41
42
43
44
45
45
46
PART NO.
PART NAME
PLUG
QTY.
REMARKS
0802011104
0150000018
0016906016
D2322400004
0199900550
0199900700
0199900500
0605515094
0805010004
1552053004
0602021190
0192200400
0605515081
0605515003
0605515159
0802081403
0602081104
1622082104
0016906025
0016906016
7222016304
0199900650
0199900650
0605515094
2
2
4
1
1
1
O-RING A P18
HEX HEAD BOLT
HOSE JOINT
DRAIN HOSE
DRAIN HOSE
DRAIN HOSE.....................................................1................DA7000SSA
HOSE BAND, Ø12
DRAIN JOINT
JOINT BOLT
PACKING SW22
DRAIN HOSE
HOSE BAND
4
1
1
2
1
1
1
HOSE BAND, Ø27
HOSE BAND, Ø32 .............................................1................DA7000SSA
RESERVE TANK
CAP RESERVE TANK
BRACKET RESERVE TANK
HEX HEAD BOLT
HEX HEAD BOLT
HOSE
1
1
1
1
2
1
1
HOSE
HOSE.................................................................1................DA7000SSA
HOSE BAND, Ø12
2
NOTICE
For Tier II white units Air Cleaner Assy., See Kubota
engine section in this manual.
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 73
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BATTERY ASSY.
PAGE 74 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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BATTERY ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
PART NAME
BATTERY
BATTERY SHEET
BATTERY BAND
BATTERY BOLT
WING NUT
WASHER, LOCK
WASHER, FLAT
TERMINAL ASSY. (POSITIVE)
TERMINAL ASSY. (NEGATIVE)
TERMINAL CAP
QTY.
REMARKS
0167103820
1702202104
D2345200004
0805082704
0037806000
0040006000
0041206000
0602220310
0602220311
0602220600
1
1
1
2
2
2
2
1
1
1
9
10
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 75
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MUFFLER ASSY.
PAGE 76 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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MUFFLER ASSY.
NO.
1
2
3
4
5
6
7
PART NO.
PART NAME
MUFFLER
HEX. HEAD BOLT
EXHAUST PIPE
QTY.
REMARKS
D2332100003
0016908020
D2335000003
1526312371
1502336004
0207008000
0016908035
1
4
1
GASKET ............................................................1................REPLACES 1526312371
GASKET
HEX. NUT
HEX. HEAD BOLT
1
4
2
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 77
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FUEL TANK ASSY.
PAGE 78 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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FUEL TANK ASSY.
NO.
1
1A
1B
2
3
4
5
6
7
8
8
9
10
11
12
13
14
15
15A
16
17
18
19
20
21
22
23
24
PART NO.
PART NAME
FUEL TANK
CAP, FUEL TANK
FUEL FILTER
FUEL GAUGE
TANK BAND
PAD, TANK BANK
HEX. HEAD BOLT
HEX. NUT
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL.................................. 1..................DA7000SSA
DRAIN JOINT
PLUG
O-RING A P18
HEX. HEAD BOLT
DRAIN HOSE
HOSE BAND F-12
FUEL FILTER ASSY........................... 1..................REPLACES0602042460AND1553143012
ELEMENT, FUEL FILTER .................. 1..................REPLACES0602042171AND1523143563
BRACKET, FUEL FILTER
HEX. HEAD BOLT
HEX. HEAD BOLT
SUCTION HOSE................................ 1..................REPLACES 0605513158
SUCTION HOSE................................ 1..................REPLACES 0605513101
RETURN HOSE................................. 1..................REPLACES 0605514101
RETURN HOSE................................. 1..................REPLACES 0605514102
HOSE BAND...................................... 4..................REPLACES 0605515070
HOSE BAND...................................... 4..................REPLACES 0605515072
QTY.
REMARKS
D2365000013
0810105800
0810105900
0602125033
D2365200004
0805003414
0016906016
0207308000
D1490600104
1615511204
B9312400004A
7812014003
0802011104
0150000018
0016906016
0199900670
0605515094
1553143010
1523143560
D2368700004
0016906016
0016908065
0966180240
0966180400
0966140320
0966140240
1491142750
1024442320
1
1
1
1
2
4
2
2
1
1
1
1
1
2
1
2
1
2
1
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 79
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OIL FILTER RETROFIT ASSY.
WHISPERWATT
7K
W
AC
DA
Model
-7000SS
ON
RU
N
ST
OP
HE
AT
OF
F
IDL
E
C
ON
TRO
AC
L
VO
LT
ME
TE
AC
BR
R
CIR
CU
IT
EA
KE
R
ST
ART
00
HO
0
00
7000
W
DIESEL
AT
T
UR
S
POWERED
ST
AR
TER SWITCH
HO
AC
UR
GENERA
TOR
METE
R
20A
25A
25A
120V
25A
120/240V
PART OF
ENCLOSURE
10
12
9
15
8
13
7
6
4
3
ENGINE
PAGE 80 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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OIL FILTER RETROFIT ASSY.
NO.
3
4
PART NO.
148002003
010601000
149149001
PART NAME
ADAPTER FILTER
HOSE KIT
BRACKET ................................. 1............... INCLUDES ITEMS W/#
BOLT ......................................... 4............... NOT SOLD SEPARATELY
LOCKWASHER......................... 4............... NOT SOLD SEPARATELY
QTY.
1
1
REMARKS
6
7#
8#
9
10
12
13
15
DA7000NUT
DA7000LOCKWASHER LOCKWASHER
DA7000BOLT
149002000
7000015241
NUT
3
3
3
1
1
BOLT
FILTERHEAD
SPIN-ON OIL FILTER
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 81
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ENCLOSURE ASSY.
PAGE 82 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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ENCLOSURE ASSY.
NO.
1
1A
2
3
4
PART NO.
PART NAME
QTY.
REMARKS
A5415000202
D2492100004
D2415100004
0016906016
A5415600104
0016906016
D2455200113
BASE ........................................................1 ...............SEE ORDER CODE CHART BELOW
LINING
FLOOR PANEL .........................................1 ...............SEE ORDER CODE CHART BELOW
HEX HEAD BOLT
DUCT........................................................1 ...............SEE ORDER CODE CHART BELOW
HEX HEAD BOLT
SPLASHER PANEL ..................................1 ...............SEE ORDER CODE CHART BELOW
1
4
5
6
4
7
D2455200003A SPLASHER PANEL ..................................1 ...............REPLACES P/N D2455200003
....................................................................................SEE ORDER CODE CHART BELOW
8
9
0016906016
HEX HEAD BOLT
12
D2425000012B FRONT FRAME, (ORANGE UNITS) ........1 ...............REPLACES P/N D2425000012
....................................................................................S/N 3757609 AND BELOW
9
D2425000022
0220900340
0016906016
0016908020
D2312100004
0016906016
D2312300013
FRONT FRAME, (WHITE UNITS) ............1 ...............S/N 3757610 AND ABOVE
9A
10
11
12
13
14
RUBBER SEAL
HEX HEAD BOLT
HEX HEAD BOLT
BRACKET RADIATOR
HEX HEAD BOLT
FAN SHROUD
LINING
LINING
LINING
HEX HEAD BOLT
2
3
2
1
2
1
1
4
4
4
14-1 D2492200004
14-2 0221700050
14-3 0221900165
15
16
17
18
19
20
21
21
22
23
24
0016906016
A5435300203
A5435300403
0012310025
D2485500014
0016906016
A5445000102
A5445000112
0016906016
D2445300004
0016906016
HANGER...................................................1 ...............SEE ORDER CODE CHART BELOW
HANGER...................................................1 ...............SEE ORDER CODE CHART BELOW
HEX HEAD BOLT
HARNESS GUIDE
HEX HEAD BOLT
REAR FRAME, (ORANGE UNITS)
REAR FRAME, (WHITE UNITS)
HEX HEAD BOLT
8
1
2
1
1
4
COVER REAR FRAME.............................1 ...............SEE ORDER CODE CHART BELOW
HEX HEAD BOLT
6
ORDER CODE CHART
THE PART NUMBER ABOVE INDICATES DEFAULT
COLOR OF ORANGE. TO ORDER WITH DIFFERENT
COLOR, PLEASE ADD THE FOLLOWING LETTERS
WITH THE PART NUMBER:
MQW-WHITE
Unit serial number may be required
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 83
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ENCLOSURE ASSY.
PAGE 84 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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ENCLOSURE ASSY.
NO.
25
25
26
27
28
29
29A
30
30A
30A
31
32
33
34
35
36
37
38
38
39
40
41
42
43
44
45
46
PART NO.
PART NAME
QTY.
1
1
15
REMARKS
A5465000102
A5465000112
0016906016
8432081004
0016906016
D245500113
A5495400704
D2455000013
A5495400704
A5495400604
0605010215
0021805016
0810014704
0080200004
D2455700004
7835088004
0016908020
A5445200003
A5445200013
0601851613
0810014704
0080200004
8511864604
0016906016
0601851660
97535K25
ROOF PANEL, (ORANGE UNITS)
ROOF PANEL, (WHITE UNITS)
HEX HEAD BOLT
COVER RADIATOR CAP..........................1 ...............SEE ORDER CODE CHART BELOW
HEX HEAD BOLT
SIDE DOOR
LINING
2
1
1
SIDE DOOR..............................................1 ...............SEE ORDER CODE CHART BELOW
LINING, (ORANGE UNITS)
LINING, (WHITE UNITS)
DOOR HANDLE
MACHINE SCREW
PIN
SNAP RING
DOOR STAY
COLLAR
HEX HEAD BOLT
REAR DOOR, (ORANGE UNITS)
REAR DOOR, (WHITE UNITS)
STOPPER
PIN
SNAP RING
1
1
2
8
4
4
2
2
2
1
1
2
2
2
1
5
2
TERMINAL PLATE
HEX HEAD BOLT
STOPPER
CAP, 4-INCH FUEL FILL...........................1 ...............OPTION
CAP, 3-INCH FUEL GAUGE .....................1 ...............OPTION
97535K21
ORDER CODE CHART
THE PART NUMBER ABOVE INDICATES DEFAULT
COLOR OF ORANGE. TO ORDER WITH DIFFERENT
COLOR, PLEASE ADD THE FOLLOWING LETTERS
WITH THE PART NUMBER:
MQW-WHITE
Unit serial number may be required
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 85
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RUBBER SEALS ASSY.
PAGE 86 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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RUBBER SEALS ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
PART NAME
QTY.
REMARKS
0229400470
0229400760
0222900325
0222900125
0222600100
0228300600
0228300200
0228300550
0227600130
0227600500
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
4
2
2
4
4
1
2
2
2
2
9
10
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 87
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KUBOTA Z482-EB/E2B/E3B ENGINE — CRANKCASE ASSY.
PAGE 88 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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KUBOTA Z482-EB/E2B/E3B ENGINE — CRANKCASE ASSY.
CRANKCASE ASSY.
NO.
010
010
010
PART NO.
PART NAME
QTY.
REMARKS
1685301012
1685301017
1685301019
COMP. CRANKCASE, Z482-EB ........................1................INCLUDES ITEMS W/$
COMP. CRANKCASE, Z482-E2B ......................1................INCLUDES ITEMS W/#
COMP. CRANKCASE, Z482-E3B ......................1................INCLUDES ITEMS W/%
020$#% 1685196260
030$#% 1685196270
040$#% 1545196270
050$#% 1526196010
060$#% 1552196020
070$#% 1552196030
080$#% 1526196160
090$#% 0501200508
100$#% 0501200814
110$#% 1522133650
120$#% 1523133960
130$#% 1733159190
140$#% 1685116212
CAP, SEALING
CAP, SEALING
CAP, SEALING
PLUG
PLUG
PLUG
PLUG, EXPANSION
PIN, STRAIGHT
PIN, STRAIGHT
PIN, PIPE
PIN, PIPE
PIN, PIPE
COVER, FUEL CAMSHAFT
3
3
2
4
1
1
1
2
2
1
2
2
1
150# 1522133700
160$#% 1584773130
O-RING..............................................................1................Z482-E2B ONLY
JOINT, DRAIN PIPE
1
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 89
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KUBOTA Z482-EB/E2B/E3B ENGINE — OIL PUMP ASSY.
PAGE 90 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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KUBOTA Z482-EB/E2B/E3B ENGINE — OIL PUMP ASSY.
OIL PUMP ASSY.
NO.
010
010
020
030
040
050
060
PART NO.
PART NAME
OIL PUMP ASSY................................................1................Z482-EB
OIL PUMP ASSY................................................1................Z482-E2B AND Z482-E3B
QTY.
REMARKS
1685135010
1685135012
1685135152
1584191050
1584135660
0571200408
0278350100
GASKET, OIL PUMP NA
BOLT
GEAR, OIL PUMP DRIVE
KEY, FEATHER
NUT, FLANGE
1
3
1
1
1
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 91
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KUBOTA Z482-EB/E2B/E3B ENGINE — OIL PAN ASSY.
PAGE 92 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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KUBOTA Z482-EB/E2B/E3B ENGINE — OIL PAN ASSY.
OIL PAN ASSY.
NO.
010
020
030
030
040
050
060
070
PART NO.
PART NAME
COMP. OIL PAN
BOLT
QTY.
1
1
REMARKS
1756101505
0112360814
0102350612
0102350614
1654133750
1545196670
1685132110
0481400160
BOLT.................................................................14...............Z482-EB AND Z482-E2B
BOLT.................................................................14...............Z482-E3B
PLUG, DRAIN
GASKET
FILTER, OIL
O-RING
1
1
1
1
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 93
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KUBOTA Z482-EB/E2B/E3B ENG. — CYLINDER HEAD ASSY.
PAGE 94 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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KUBOTA Z482-EB/E2B/E3B ENG. — CYLINDER HEAD ASSY.
CYLINDER HEAD ASSY.
NO.
010
020
020
030
030
030
PART NO.
PART NAME
HOOK, ENGINE
QTY.
REMARKS
1522101750
0112360816
0112350816
1685503042
1G95703023
1G68903040
2
BOLT..................................................................2................Z482-EB
BOLT..................................................................2................Z482-E2B AND Z482-E3B
COMP. CYLINDER HEAD, Z482-EB..................1................INCLUDES ITEMS W/#
COMP. CYLINDER HEAD, Z482-E2B................1................INCLUDES ITEMS W/%
COMP. CYLINDER HEAD, Z482-E3B................1................INCLUDES ITEMS W/$
CAP, SEALING...................................................1................Z482-EB AND Z482-E3B
CAP, SEALING...................................................1................Z482-E2B
PLUG
GUIDE, INLET VALVE
GUIDE, EXHAUST VALVE
040#%$ 1532196260
045%$ 1526103370
050#%$ 1526196010
060#%$ 1584113540
070#%$ 1584113560
1
2
2
080#
090
100
100
110
1584196020
1460103450
1685103310
1685103312
1522133700
PLUG .................................................................1................Z482-EB
BOLT, CYLINDER HEAD
GASKET, CYLINDER HEAD
10
1
GASKET, CYLINDER HEAD..............................1................Z482-EB
O-RING..............................................................1................Z482-E2B AND Z482-E3B
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 95
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KUBOTA Z482-EB/E2B/E3B ENGINE — GEAR CASE ASSY.
PAGE 96 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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KUBOTA Z482-EB/E2B/E3B ENGINE — GEAR CASE ASSY.
GEAR CASE ASSY.
NO.
010
010
PART NO.
1687504024
1E05104024
PART NAME
QTY.
REMARKS
COMP. CASE, GEAR, Z482EB, Z482E2B.........1................INCLUDES ITEMS W/#
COMP. CASE, GEAR, Z482E3B........................1................INCLUDES ITEMS W/%
PLUG .................................................................2................Z482EB
PLUG .................................................................2................Z482-E2B AND Z482-E3B
PIN, START SPRING
020#% 1685196010
020#% 1552196030
030#% 1584156280
1
040
050
050
060
070
080
090
090
100
130
150
160
170
180
190
200
210
220
230
240
0481406130
1586204132
1586204130
0102350618
0102360650
1584191010
0102350670
0102360670
0102350675
1587704140
1685136950
1584136930
0771503211
1584633110
1381133140
0481106230
1946188132
1522188210
0205650060
0451260060
O-RING..............................................................3................Z482-EB AND Z482-E2B
GASKET, GEAR CASE .....................................1................Z482-EB AND Z482-E2B
GASKET, GEAR CASE .....................................1................Z482-E3B
BOLT
BOLT
BOLT
1
8
5
BOLT..................................................................1................Z482EB
BOLT..................................................................1................Z482E2B AND Z482-E3B
BOLT
SEAL, OIL
SPRING
SEAT, VALVE
BALL
FLANGE, OIL FILLER
PLUG, OIL FILLER
O-RING
GASKET, H/M GEAR CASE
STUD
NUT
1
1
1
1
1
1
1
1
1
3
3
3
WASHER, LOCK
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 97
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KUBOTA Z482-EB/E2B/E3B ENGINE — HEAD COVER ASSY.
PAGE 98 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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KUBOTA Z482-EB/E2B/E3B ENGINE — HEAD COVER ASSY.
HEAD COVER ASSY. (Z482-EB)
NO.
010
020
030
040
050
060
070
080
090
100
110
120
130
140
150
160
PART NO.
PART NAME
QTY.
REMARKS
1588105550
1584105140
1584105150
1584105670
1584105370
1686193310
1584705512
1584105590
0211450080
0401360080
1685114512
1685114522
1584114620
1560196650
1585233140
0481150300
JOINT, BREATHER PIPE
PLATE, BREATHER ELEMENT
PLATE, BREATHER ELEMENT
ELEMENT, BREATHER
OIL SHIELD, BREATHER
SCREW
PIPE, BREATHER
CLAMP, PIPE
NUT
1
1
1
1
1
2
1
1
1
2
WASHER, FLATT
COVER, CYLINDER HEAD ...............................1................Z482-EB
GASKET, HEAD COVER
NUT, CAP
GASKET
PLUG, OIL FILLER
O-RING
1
2
2
1
1
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 99
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KUBOTA Z482-EB/E2B/E3B ENGINE — HEAD COVER ASSY.
PAGE 100 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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KUBOTA Z482-EB/E2B/E3B ENGINE — HEAD COVER ASSY.
HEAD COVER ASSY. (Z482-E2B/Z482-E3B)
NO.
010
010
PART NO.
1G95714503
1G95714504
PART NAME
QTY.
REMARKS
COVER CYLINDER HEAD, Z482-E2B ..............1................INCLUDES ITEMS W/#
COVER CYLINDER HEAD, Z482-E3B ..............1................INCLUDES ITEMS W/%
020# 1624173370
030# 1G91105203
040# 1G80105120
050# 0302450510
060# 1G95805370
070# 1G95714520
PIPE, WATER RETURN
COMP. VALVE BREATHER
COVER, BREATHER
SCREW WITH WASHER
SHIELD, BREATHER.........................................1................Z482-E2B
GASKET, HEAD COVER
BOLT
TUBE, BREATHER
CLAMP, HOSE
PLUG, OIL FILTER
O-RING
1
1
1
4
1
4
1
2
1
1
080
090
100
120
130
1G91191022
1G96005512
0931888125
E915133140
0481450300
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 101
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KUBOTA Z482-EB/E2B/E3B ENGINE — OIL FILTER ASSY.
PAGE 102 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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KUBOTA Z482-EB/E2B/E3B ENGINE — OIL FILTER ASSY.
OIL FILTER ASSY.
NO.
010
010
020
030
PART NO.
PART NAME
QTY.
REMARKS
7000015241
1585332430
1584194010
1524132290
CARTRIDGE, OIL FILTER, Z482-EB.................1................REPLACES P/N 1585399170
CARTRIDGE, OIL FILTER.................................1................Z482-E2B AND Z482-E3B
WASHER, FLAT
JOINT, PIPE
1
1
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 103
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KUBOTA Z482-EB/E2B/E3B ENG. — DIPSTICK AND GUIDE ASSY.
PAGE 104 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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KUBOTA Z482-EB/E2B/E3B ENG. — DIPSTICK AND GUIDE ASSY.
DIPSTICK AND GUIDE ASSY.
NO.
010
010
020
PART NO.
PART NAME
GAUGE, OIL ......................................................1................Z482-EB
GAUGE, OIL ......................................................1................Z482-E2B AND Z482-E3B
GUIDE, OIL GAUGE..........................................1................Z482-E2B AND Z482-E3B
QTY.
REMARKS
1685136410
1G30436410
1745636420
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 105
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KUBOTA Z482-EB/E2B/E3B ENG. — MAIN BEARING CASE ASSY.
PAGE 106 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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KUBOTA Z482-EB/E2B/E3B ENG. — MAIN BEARING CASE ASSY.
MAIN BEARING CASE ASSY.
NO.
010
010
PART NO.
1685104092
1685107090
PART NAME
QTY.
REMARKS
ASSY. CASE, MAIN BEARING, Z482-EB/E2B..1................INCLUDES ITEMS W/@
ASSY. CASE, MAIN BEARING, Z482-E3B........1................INCLUDES ITEMS W/$
015@$ 1686123480
020@$ 1584104540
METAL, CRANKSHAFT M
BOLT, BEARING CASE
GASKET, BEARING CASE
COVER ASSY., BRG CASE, Z482-EB ..............1................INCLUDES ITEMS W/#
COVER ASSY., BRG CASE, Z482-E2B/E3B.....1................INCLUDES ITEMS W/%
COVER, BEARING CASE .................................1................Z482-EB
1
2
1
030
035
035
1585204360
1584104800
1584104803
040# 1584104810
040% 1584104815
050#% 1921599160
COVER, BEARING CASE .................................1................Z482-E2B AND Z482-E3B
SEAL, OIL
1
060
060
070
080
090
090
100
110
1584104822
1584104823
0102350620
0102350622
1685104040
1685107040
1584104540
1584104562
GASKET, CASE COVER ...................................1................Z482-EB AND Z482-E2B
GASKET, CASE COVER ...................................1................Z482-E3B
BOLT
BOLT
8
8
ASSY. CASE, MAIN BEARING..........................1................Z482-EB AND Z482-E2B
ASSY. CASE, MAIN BEARING..........................1................Z482-E3B
BOLT, BEARING CASE
BOLT, BEARING CASE
2
1
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 107
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KUBOTA Z482-EB/E2B/E3B ENGINE — CAMSHAFT AND IDLE GEAR ASSY.
PAGE 108 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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KUBOTA Z482-EB/E2B/E3B ENGINE — CAMSHAFT AND IDLE GEAR ASSY.
CAMSHAFT AND IDLE GEAR SHAFT ASSY.
NO.
010
010
020
030
030
PART NO.
PART NAME
TAPPET .............................................................4................Z482-EB
QTY.
REMARKS
1685115550
1685115552
1685115110
1584116015
1584116019
TAPPET .............................................................4................Z482-E2B AND Z482-E3B
PUSH ROD
4
CAMSHAFT ASSY.............................................1................INCLUDES ITEMS W/%
CAMSHAFT ASSY.............................................1................INCLUDES ITEMS W/$
SCREW, SET.....................................................1................Z482-EB
040$ 1552193610
040A% 0771500401
050%$ 1686416510
060%$ 0571200518
070%$ 1584116270
BALL ..................................................................1................Z482-E2B AND Z482-E3B
GEAR, CAM
1
1
1
2
KEY, FEATHER
STOPPER, CAMSHAFT
BOLT
080
090
0102350612
1587524013
COMP. GEAR, IDLE...........................................1................INCLUDES ITEMS W/#
100# 1587524282
BUSH
1
1
1
1
3
120
130
140
150
1587524370
1587524320
1587524250
0102350614
COLLAR, IDLE GEAR
RING, SNAP
SHAFT, IDLE GEAR
BOLT
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 109
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KUBOTA Z482-EB/E2B/E3B ENG. — PISTON AND CRANKSHAFT ASSY.
PAGE 110 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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KUBOTA Z482-EB/E2B/E3B ENG. — PISTON AND CRANKSHAFT ASSY.
PISTON AND CRANKSHAFT ASSY.
NO.
010
010
010
010
020
020
030
040
050
050
PART NO.
PART NAME
QTY.
REMARKS
1685121112
1685121114
1685121900
1685121903
1685321050
1685321090
1685121310
1526121330
1685122010
1685122015
PISTON STD ...................................................2................Z482-EB AND Z482-E2B
PISTON STD ...................................................2................Z482-E3B
PISTON +0.25MM..............................................2................Z482-EB AND Z482-E2B
PISTON +0.25MM..............................................2................Z482-E3B
ASSY. PISTON RING STD
ASSY. PISTON RING +0.25MM
PIN, PISTON
2
2
2
4
AIR CLIP, PISTON PIN
CONNECTING ROD ASSY., Z482-EB...............2................INCLUDES ITEMS W/%
CONN. ROD ASSY. Z482-E2B/E3B...................2................INCLUDES ITEMS W/+
BUSH, PISTON PIN...........................................2................Z482-EB
BUSH, PISTON PIN...........................................2................Z482-E2B AND Z482-E3B
BOLT, CONNECTING ROD
METAL, CRANKPIN M STD SET
METAL, CRANKPIN -0.20MM SET
METAL, CRANKPIN -0.40MM SET
060% 1685121980
060+ 1685121982
070%+ 1685122140
080%+ 1685122320
080
080
090
4
2
2
2
1586122970
1586122980
1685323030
CRANKSHAFT ASSY.........................................1................INCLUDES ITEMS W/#
100# 0771503207
110# 1921523280
BALL
2
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
1
1
1
SLEEVE, CRANKSHAFT
GEAR, CRANK
KEY, FEATHER
120
130
140
140
140
150
150
150
160
160
160
170
170
170
180
180
180
190
200
210
1584124110
0571200515
1586123470
1586123910
1586123920
1686123480
1569423930
1569423940
1686123490
1586123860
1586123870
1526123530
1526123950
1526123960
1526123540
1526123970
1526123980
1584123250
1588123310
0481416220
METAL, CRANKSHAFT STD
METAL, CRANKSHAFT -0.20MM
METAL, CRANKSHAFT -0.40MM
METAL, CRANKSHAFT M STD SET
METAL, CRANKSHAFT -0.20MMSET
METAL, CRANKSHAFT -0.40MMSET
METAL, CRANKSHAFT STD SET
METAL, CRANKSHAFT -0.20MM SET
METAL, CRANKSHAFT -0.40MM SET
METAL, SIDE STD
METAL, SIDE +0.20MM
METAL, SIDE +0.40MM
METAL, SIDE STD
METAL, SIDE +0.20MM
METAL, SIDE +0.40MM
COLLAR, CRANKSHAFT
SLINGER, OIL
O-RING
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 111
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KUBOTA Z482-EB/E2B/E3B ENGINE — FLYWHEEL ASSY.
PAGE 112 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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KUBOTA Z482-EB/E2B/E3B ENGINE — FLYWHEEL ASSY.
FLYWHEEL ASSY.
NO.
010
010
PART NO.
1685125010
1685125015
PART NAME
QTY.
REMARKS
COMP. FLYWHEEL, Z482-EB............................1................INCLUDES ITEMS W/#
COMP. FLYWHEEL, Z482-E2B/E3B..................1................INCLUDES ITEMS W/%
020# 1685163820
020% 1685163822
GEAR, RING, Z482-EB
GEAR, RING, Z482-E2B AND Z482-E3B
BOLT, FLYWHEEL
HOUSING, FLYWHEEL
BOLT
COVER
BOLT
WASHER, FLAT
1
1
5
1
10
1
030
050
060
070
080
090
1585225160
1584704612
0112350820
3122014170
0112360814
0401360080
1
1
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 113
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KUBOTA Z482-EB/E2B/E3B ENG. — FUEL CAMSHAFT & GOV. SHAFT ASSY.
PAGE 114 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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KUBOTA Z482-EB/E2B/E3B ENG. — FUEL CAMSHAFT & GOV. SHAFT ASSY.
FUEL CAMSHAFT AND GOVERNOR SHAFT ASSY.
NO.
010
010
PART NO.
1685116020
1685116023
PART NAME
QTY.
REMARKS
CAMSHAFT ASSY., FUEL, Z482-EB/E2B.........1................INCLUDES ITEMS W/#
CAMSHAFT ASSY., FUEL, Z482-E3B...............1................INCLUDES ITEMS W/$
020# 1584116172
030# 0815306203
040# 1685151150
050# 0571200515
060# 1584155450
060# 1584155452
070# 1584155690
080# 0771500801
090# 1526155470
100# 0771503217
CAMSHAFT, FUEL
BEARING, BALL
GEAR, INJECTION PUMP
KEY, FEATHER
SLEEVE, GOVERNOR......................................1................Z482-EB AND Z482-E2B
SLEEVE, GOVERNOR......................................1................Z482-E3B
CASE, GOVERNOR BALL
BALL
1
1
1
1
1
32
1
CIR-CLIP, GOVERNOR SLEEVE
BALL
BEARING, BALL................................................1................Z482-EB
8
110
110
120
130
140
0810306203
1687197300
0461200170
1584116320
0102350612
BEARING, BALL................................................1................Z482-E2B AND Z482-E3B
CIR CLIP, EXTERNAL
STOPPER, FUEL. CAMSHAFT
BOLT
1
1
2
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 115
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KUBOTA Z482-EB/E2B/E3B ENG. — ENG. STOP LEVER ASSY.
PAGE 116 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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KUBOTA Z482-EB/E2B/E3B ENG. — ENG. STOP LEVER ASSY.
ENGINE STOP LEVER ASSY.
NO.
010
PART NO.
1584154092
PART NAME
ASSY. APPARATUS, IDLE .................................1................INCLUDES ITEMS W/#
QTY.
REMARKS
020# 1584154100
030# 1526192020
040# 1584154220
050# 1502133660
ASSY. BOLT, ADJUSTING
NUT
NUT, CAP
GASKET
CAP
BOLT, ADJUSTING............................................1................Z482-EB
BOLT, ADJUSTING............................................1................Z482-E2B AND Z482-E3B
NUT, LOCK
GASKET ............................................................2................Z482-EB
GASKET ............................................................1................Z482-E2B AND Z482-E3B
GASKET ............................................................1................Z482-E2B/Z482-E3B ONLY
NUT, CAP
PIPE, LOCK.......................................................1................Z482-EB ONLY
1
1
1
2
1
060
070
070
080
090
090
095
100
110
1584154270
1584154122
1584154123
1G03154210
1560196650
1560196650
1G02196650
1584192330
1G02154290
1
1
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 117
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KUBOTA Z482-EB/E2B/E3B ENG. — STOP SOLENOID ASSY.
PAGE 118 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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KUBOTA Z482-EB/E2B/E3B ENG. — STOP SOLENOID ASSY.
STOP SOLENOID ASSY.
NO.
010
010
010
020
PART NO.
PART NAME
QTY.
REMARKS
1685160010
1685160013
1685160014
0175450612
SOLENOID, STOP.............................................1................Z482-EB
SOLENOID, STOP.............................................1................Z482-E2B
SOLENOID, STOP.............................................1................Z482-E3B
BOLT, FLANGE
2
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 119
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KUBOTA Z482-EB/E2B/E3B ENG. — INJECTION PUMP ASSY.
PAGE 120 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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KUBOTA Z482-EB/E2B/E3B ENG. — INJECTION PUMP ASSY.
INJECTION PUMP ASSY.
NO.
010
020
020
020
020
020
030
040
050
060
070
080
PART NO.
PART NAME
PUMP ASSY., INJECTION ................................1................INCLUDES ITEMS W/%
QTY.
REMARKS
1600151010
1600152090
1600152110
1600152120
1G68952160
1G68952200
0131110620
1584191500
1584192320
0451260060
1584195680
1526342010
SHIM, INJECTION PUMP, 20 MM
SHIM, INJECTION PUMP, 25 MM
SHIM, INJECTION PUMP, 30 MM
1
1
1
SHIM, INJECTION PUMP, 35 MM .....................1................Z482-E3B ONLY
SHIM, INJECTION PUMP, 175 MM ...................1................Z482-E3B ONLY
BOLT, HEX-SOC-HD
STUD
NUT, CAP
WASHER, LOCK
JOINT, EYE
3
1
1
4
1
ASSY. PIPE, FUEL.............................................1................INCLUDES ITEMS W/#
090# 1491142750
095# 6659154250
100% 1584151320
110% 1584196650
120% 1584151350
130% 1584196660
CLIP, PIPE
SPRING, PIPE PROTECT
SCREW HOLLOW.............................................1................Z482-E2B /Z482-E3B ONLY
GASKET ............................................................2................Z482-E2B AND Z482-E3B ONLY
SCREW..............................................................1................Z482-E2B AND Z482-E3B ONLY
GASKET ............................................................1................Z482-E2B AND Z482-E3B ONLY
2
1
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 121
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KUBOTA Z 482-EB ENGINE—INJECTION PUMP COMPONENTS ASSY.
PAGE 122 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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KUBOTA Z 482-EB ENGINE—INJECTION PUMP COMPONENTS ASSY.
INJECTION PUMP COMPONENTS ASSY.
NO.
010
010
PART NO.
1600151010
1754851010
PART NAME
QTY.
REMARKS
INJECTION PUMP ASSY., Z482-EB .................1................INCLUDES ITEMS W/#
INJECTION PUMP ASSY., Z482-E2B/E3B .......1................INCLUDES ITEMS W/%
020# 1685151050
020% 1754851050
030# 1584151030
040# 1584151230
050# 1584151240
060# 1685151220
070# 1584196760
080# 1584151560
090# 1584194570
100# 1584151200
110# 1586291430
120# 1585251470
130# 1584151070
140# 1584151250
150# 1584151430
160# 1584151280
170# 1584151270
180# 1584151290
190# 1584151490
200# 1584151060
210# 1584151540
220# 1584193110
230# 1584151380
240# 1584151320
250# 1584196650
260# 1584151350
270# 1584196660
PLUNGER, PUMP, Z482-EB
PLUNGER, PUMP, Z482-E2B/E3B
VALVE, DELIVERY
SPRING, DELIV. VALVE
GASKET, DELIV. VALVE
HOLDER, DELIV. VALVE
O-RING
FLANGE, SLEEVE
PIN, JOINT
O-RING
SCREW
WASHER
ASSY. TAPPET
PIN, TAPPET GUIDE
PIN, CLAMP
SPRING, PLUNGER
SEAT, SPRING UPPER
SEAT, SPRING LOWER
SHIM
SHIM
PLATE
SCREW, CSK-HD
SLEEVE, CONTROL
SCREW, FOLLOW
GASKET
SCREW
GASKET
2
2
2
2
2
2
2
2
2
4
4
4
2
2
1
2
2
2
1
1
1
4
2
1
2
1
1
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 123
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KUBOTA Z482-EB/E2B/E3B ENG. — SPEED CONTROL PLATE ASSY.
PAGE 124 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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KUBOTA Z482-EB/E2B/E3B ENG. — SPEED CONTROL PLATE ASSY.
SPEED CONTROL PLATE ASSY.
NO.
010
PART NO.
1584157110
PART NAME
PLATE, SPEED CONTROL ...............................1................Z482-EB
QTY.
REMARKS
010% 1584157112
PLATE, SPEED CONTROL ...............................1................Z482-E2B AND Z482-E3B
020
030
040
040
050
060
1584157212
0102350618
0105350618
1687191050
1560196650
1584156110
GASKET, CONTROL PLATE
BOLT
BOLT..................................................................2................Z482-EB AND Z482-E2B
BOLT..................................................................2................Z482-E3B
GASKET ............................................................2................Z482-EB AND Z482-E2B
LEVER, GOVERNOR ........................................1................Z482-EB
1
2
060% 1584156112
LEVER, GOVERNOR ........................................1................Z482-E2B AND Z482-E3B
COLLAR.............................................................1................Z482-EB
COLLAR.............................................................1................Z482-E2B AND Z482-E3B
070
070
1584157240
1928057240
080% 0481410160
090% 1666757150
O-RING
LEVER, SPEED CONTROL
1
1
100
100% 1686692010
110 1687857740
110% 1687857742
120 1685157720
120% 1685157724
130 0541100318
130% 0541100314
140% 0481410070
150% 1687857920
1584192010
NUT, SPEED CONTROL ...................................2................Z482-EB
NUT, SPEED CONTROL ...................................2................Z482-E2B AND Z482-E3B
SHAFT, LEVER..................................................1................Z482-EB
SHAFT, LEVER..................................................1................Z482-E2B AND Z482-E3B
LEVER, ENGINE STOP.....................................1................Z482-EB
LEVER, ENGINE STOP.....................................1................Z482-E2B AND Z482-E3B
PIN, SPRING .....................................................1................Z482-EB
PIN, SPRING .....................................................1................Z482-E2B AND Z482-E3B
O-RING
SPRING, RETURN
1
1
160
1686657300
CAP....................................................................1................Z482-EB
160% 1686657302
170% 1756157013
180% 1920291010
190% 1920291010
200% 0205650060
CAP....................................................................1................Z482-E2B AND Z482-E3B
COMP. PLATE, SPEED CO................................1................INCLUDES ITEMS W%
BOLT..................................................................2................Z482-E3B ONLY
BOLT..................................................................3................Z482-E3B ONLY
NUT....................................................................3................Z482-E3B ONLY
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 125
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KUBOTA Z482-EB/E2B/E3B ENG. — NOZZLE HOLDER AND GLOW ASSY.
PAGE 126 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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KUBOTA Z482-EB/E2B/E3B ENG. — NOZZLE HOLDER AND GLOW ASSY.
NOZZLE HOLDER AND GLOW PLUG ASSY.
NO.
010
020
PART NO.
1585242502
1584142500
PART NAME
PIPE ASSY., OVER FLOW
QTY.
REMARKS
1
PIPE ASSY., OVER FLOW ................................1................INCLUDES ITEMS W/#
025# 1584142520
030# 1497142750
PIPE, FUEL OVER FLOW
CLIP, PIPE
SCREW, AIR BREATHER
GASKET
KIT, HOLDER NOZZLE
HOLDER ASSY., NOZZLE
GASKET
1
2
1
1
2
2
2
2
040
050
055
060
070
075
090
090
090
100
100
100
110
120
130
140
140
150
160
170
1584151360
1560196650
1600153900
1600153000
1584153622
1907753650
1685153712
1685153713
1G68653710
1685153722
1685153723
1G68653720
1584153850
1584153860
0302450520
1685165510
1685165512
1685165560
0276150040
0401360040
SEAL, HEAT
PIPE, INJECTION..............................................1................Z482-EB
PIPE, INJECTION..............................................1................Z482-E2B
PIPE, INJECTION..............................................1................Z482-E3B
PIPE, INJECTION..............................................1................Z482-EB
PIPE, INJECTION..............................................1................Z482-E2B
PIPE, INJECTION..............................................1................Z482-E3B
CLAMP, PIPE
CLAMP, PIPE
SCREW, WITH WASHER
GLOW PLUG .....................................................2................Z482-EB
GLOW PLUG .....................................................2................Z482-E2B AND Z482-E3B
CORD, GLOW PLUG
NUT, FLANGE
1
1
1
1
2
WASHER, FLAT.................................................2................Z482-EB ONLY
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 127
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KUBOTA Z482-EB/E2B/E3B ENGINE — NOZZLE HOLDER ASSY.
PAGE 128 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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KUBOTA Z482-EB/E2B/E3B ENGINE — NOZZLE HOLDER ASSY.
NOZZLE HOLDER ASSY.
NO.
10
PART NO.
PART NAME
ASSY. HOLDER, NOZZLE................................................2 .................. INCLUDES ITEMS W/ %
QTY.
REMARKS
1600153000
1584192030
1584153230
1584153170
1584153350
1584153160
1647553280
1584194040
1685153610
1584198100
1584153230
1584198510
1584198520
1584198530
1584198540
1584198550
1584198560
1584198570
1584198580
1584198590
1584198600
1584198610
1584198620
1584198630
1584198640
1584198650
1584198660
1584198670
1584198680
1584198690
1584198700
1584198710
1584198720
1584198730
1584198740
1584198750
1584198760
1584198770
1584198780
1584198790
1584198800
1584198810
1584198820
1584198830
1584198840
1584198850
1584198860
1584198870
1584198880
1584198890
1584198900
1584198910
1584198920
20%
30%
40%
50%
60%
70%
80%
90%
100
NUT
2
2
2
2
2
2
2
2
WASHER, ADJUSTING
SPRING, NOZZLE
PIECE, DISTANCE
PUSH ROD
NUT, NOZZLE
WASHER
PIECE NOZZLE
ASSY. WASHER, ADJUST................................................2 .................. INCLUDES ITEMS W/#OPTION
WASHER, ADJUSTING....................................................2 .................. 0.900MM
WASHER, ADJUSTING....................................................2 .................. 0.925MM
WASHER, ADJUSTING....................................................2 .................. 0.950MM
WASHER, ADJUSTING....................................................2 .................. 0.975MM
WASHER, ADJUSTING....................................................2 .................. 1.000MM
WASHER, ADJUSTING....................................................2 .................. 1.025MM
WASHER, ADJUSTING....................................................2 .................. 1.050MM
WASHER, ADJUSTING....................................................2 .................. 1.075MM
WASHER, ADJUSTING....................................................2 .................. 1.100MM
WASHER, ADJUSTING....................................................2 .................. 1.125MM
WASHER, ADJUSTING....................................................2 .................. 1.150MM
WASHER, ADJUSTING....................................................2 .................. 1.175MM
WASHER, ADJUSTING....................................................2 .................. 1.200MM
WASHER, ADJUSTING....................................................2 .................. 1.225MM
WASHER, ADJUSTING....................................................2 .................. 1.250MM
WASHER, ADJUSTING....................................................2 .................. 1.275MM
WASHER, ADJUSTING....................................................2 .................. 1.300MM
WASHER, ADJUSTING....................................................2 .................. 1.325MM
WASHER, ADJUSTING....................................................2 .................. 1.350MM
WASHER, ADJUSTING....................................................2 .................. 1.375MM
WASHER, ADJUSTING....................................................2 .................. 1.400MM
WASHER, ADJUSTING....................................................2 .................. 1.425MM
WASHER, ADJUSTING....................................................2 .................. 1.450MM
WASHER, ADJUSTING....................................................2 .................. 1.475MM
WASHER, ADJUSTING....................................................2 .................. 1.500MM
WASHER, ADJUSTING....................................................2 .................. 1.525MM
WASHER, ADJUSTING....................................................2 .................. 1.550MM
WASHER, ADJUSTING....................................................2 .................. 1.575MM
WASHER, ADJUSTING....................................................2 .................. 1.600MM
WASHER, ADJUSTING....................................................2 .................. 1.625MM
WASHER, ADJUSTING....................................................2 .................. 1.650MM
WASHER, ADJUSTING....................................................2 .................. 1.675MM
WASHER, ADJUSTING....................................................2 .................. 1.700MM
WASHER, ADJUSTING....................................................2 .................. 1.725MM
WASHER, ADJUSTING....................................................2 .................. 1.750MM
WASHER, ADJUSTING....................................................2 .................. 1.775MM
WASHER, ADJUSTING....................................................2 .................. 1.800MM
WASHER, ADJUSTING....................................................2 .................. 1.825MM
WASHER, ADJUSTING....................................................2 .................. 1.850MM
WASHER, ADJUSTING....................................................2 .................. 1.875MM
WASHER, ADJUSTING....................................................2 .................. 1.900MM
WASHER, ADJUSTING....................................................2 .................. 1.925MM
WASHER, ADJUSTING....................................................2 .................. 1.950MM
110#
110#
110#
110#
110#
110#
110#
110#
110#
110#
110#
110#
110#
110#
110#
110#
110#
110#
110#
110#
110#
110#
110#
110#
110#
110#
110#
110#
110#
110#
110#
110#
110#
110#
110#
110#
110#
110#
110#
110#
110#
110#
110#
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 129
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KUBOTA Z482-EB/E2B/E3B ENGINE — FORK LEVER ASSY.
PAGE 130 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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KUBOTA Z482-EB/E2B/E3B ENGINE — FORK LEVER ASSY.
FORK LEVER ASSY.
NO.
010
020
030
A#
PART NO.
PART NAME
SPRING, START
SPRING, GOVERNOR
LEVER, FORK ASSY.........................................1................INCLUDES ITEMS/#
LEVER, FORK COMP .......................................1................NOT SOLD SEPARATELY
HOLDER, FORK LEVER ...................................1................NOT SOLD SEPARATELY
LEVER, FORK ASSY.........................................1................INCLUDES ITEMS W/%
LEVER, FORK
SHAFT, FORK LEVER
PIN, SPRING
BOLT
QTY.
1
1
REMARKS
1685156480
1946156410
1754856054
B#
050# 1584156060
060# 1584156130
070# 1584156150
080# 0541100318
090# 1526166410
100# 0451260050
110# 1666255620
1
1
1
1
1
WASHER, LOCK
WASHER, FLAT.................................................2................Z482-E2B AND Z482-E3B ONLY
BOLT
120
0102350635
2
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 131
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KUBOTA Z482-EB/E2B/E3B ENGINE — FUEL FILTER ASSY.
PAGE 132 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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KUBOTA Z482-EB/E2B/E3B ENGINE — FUEL FILTER ASSY.
FUEL FILTER ASSY.
NO.
010
PART NO.
1553143010
PART NAME
QTY.
REMARKS
FILTER, FUEL ASSY..........................................1................INCLUDES ITEMS W/$
.............................................................................................REPLACES P/N 1553143012
COMP. BODY, COCK .........................................1................INCLUDES ITEMS W/#
LEVER, COCK
SPRING, VALVE
SCREW, SET
020$ 1553143110
030$# 1430143522
040 $# 1430143820
050$# 1430143830
060$# 1430143840
070$ 1539343100
080$% 1539343580
090*% 1687388430
100$ 1430143590
110$ 1430143650
110$ 0481600390
120$ 1523143560
120$ 1T02143560
130$ 1430143570
1
1
1
1
O-RING, LEVER
CUP ASSY., FILTER ..........................................1................INCLUDES ITEMS W/%
CUP, FILTER
LABEL, FUEL
RING, RETAINING
1
1
1
O-RING, FILTER CUP .......................................1................Z482-EB AND Z482-E2B
O-RING, FILTER CUP .......................................1................Z482-E3B ONLY
ELEMENT, FUEL FILTER ..................................1................Z482-EB AND Z482-E2B
ELEMENT, FUEL FILTER ..................................1................Z482-E3B
O-RING, FILTER
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 133
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KUBOTA Z482-EB/E2B/E3B ENGINE—FUEL PUMP ASSY.
PAGE 134 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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KUBOTA Z482-EB/E2B/E3B ENGINE—FUEL PUMP ASSY.
FUEL PUMP ASSY.
NO.
010
020
030
PART NO.
PART NAME
QTY.
REMARKS
1582152030
1626452140
0102350616
FUEL PUMP ASSY.
GASKET, FUEL PUMP
BOLT
1
1
2
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 135
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KUBOTA Z482-EB/E2B/E3B ENGINE — DYNAMO & PULLEY ASSY.
PAGE 136 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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KUBOTA Z482-EB/E2B/E3B ENGINE — DYNAMO & PULLEY ASSY.
DYNAMO AND PULLEY ASSY.
NO.
010
010
020
030
030
040
050
060
070
080
090
130
140
150
PART NO.
PART NAME
DYNAMO ASSY. ................................................1................Z482-EB
DYNAMO ASSY. ................................................1................Z482-E2B AND Z482-E3B
QTY.
REMARKS
1753164010
1753164012
1259964420
0112350830
1687191030
0115350855
0401360080
0211450080
0451260080
0401560080
0102350616
1685174280
1588191030
1980572530
STAY, DYNAMO
BOLT..................................................................1................Z482-EB
1
BOLT..................................................................1................Z482-E2B AND Z482-E3B
BOLT
1
2
1
1
WASHER, FLAT
NUT
WASHER, LOCK
WASHER, FLAT.................................................1................Z482-EB ONLY
BOLT
2
1
1
1
PULLEY, FAN DRIVE
BOLT
BELT, FAN (34.5 IN)
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 137
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KUBOTA Z482-EB/E2B/E3B ENGINE — DYNAMO ASSY.
PAGE 138 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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KUBOTA Z482-EB/E2B/E3B ENGINE — DYNAMO ASSY.
DYNAMO ASSY.
NO.
010
010
020
020
PART NO.
PART NAME
QTY.
REMARKS
1753164010
1753164012
1553164122
1553264120
DYNAMO ASSY. , Z482-EB ...........1 ........................ INCLUDES ITEMS W/%
DYNAMO ASSY. , Z482-E2B/E3B..1 ........................ INCLUDES ITEMS W/#
COMP. FLYWHEEL, Z482-EB........1 ........................ INCLUDES ITEMS W/+
COMP. FLYWHEEL, Z482-E2B/E3B .1 ........................ INCLUDES ITEMS W/<
030%#+< 1553164110
PULLEY
1
FLYWHEEL....................................1 ........................ Z482-EB
040%+
040#<
050%+
1553164040
1553264040
6C04082860
FLYWHEEL....................................1 ........................ Z482-E2B AND Z482-E3B
COLLAR.........................................1 ........................ Z482-EB
COLLAR.........................................1 ........................ Z482-E2B AND Z482-E3B
BEARING, BALL
SHAFT, FAN...................................1 ........................ Z482-EB
SHAFT, FAN...................................1 ........................ Z482-E2B AND Z482-E3B
COMP. STATOR, Z482-EB .............1 ........................ INCLUDES ITEMS W/>
COMP. STATOR, Z482-E2B/E3B ...1 ........................ INCLUDES ITEMS W/$
050#+< 1553164140
060%#+< 1553174180
2
070%+
070#<
080%
080#
1553174140
1553274140
1553164363
1553264360
090%#>$ 1526193010
100%#>$ 1553164292
SCREW, ROUND HD.
STATOR
2
1
110%>
110#$
1553164072
1553264070
PLATE............................................1 ........................ Z482-EB
PLATE............................................1 ........................ Z482-E2B AND Z482-E3B
120%#>$ 1553174180
130%#>$ 1553193010
140%#>$ 1553164190
BEARING, BALL
SCREW, ROUND HD.
CLAMP, CORD
COLLAR
NUT................................................1 ........................ Z482-EB AND Z482-E3B
NUT, FLANGE................................1 ........................ Z482-E2B
1
1
1
1
150%#
160%
160#
1526164150
1526192030
0277160100
1526194070
1526194020
170%
180%
WASHER, LOCK............................1 ........................ Z482-EB AND Z482-E3B
WASHER, FLAT.............................1 ........................ Z482-EB AND Z482-E3B
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 139
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KUBOTA Z482-EB/E2B/E3B ENGINE — STARTER ASSY.
PAGE 140 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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KUBOTA Z482-EB/E2B/E3B ENGINE — STARTER ASSY.
STARTER ASSY.
NO.
010
020
PART NO.
1983763010
0112350825
PART NAME
STARTER ASSY. 12V, 0.8KW
BOLT
QTY.
1
2
REMARKS
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 141
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KUBOTA Z482-EB/E2B/E3B ENGINE — STARTER COMP. ASSY.
PAGE 142 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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KUBOTA Z482-EB/E2B/E3B ENGINE — STARTER COMP. ASSY.
STARTER COMPONENTS ASSY.
NO.
010
020@
030@
040@
PART NO.
PART NAME
STARTER ASSY.................................................1................INCLUDES ITEMS W/@
QTY.
REMARKS
1983763010
1983763050
1585263020
1983763030
LEVER, DRIVE
SWITCH, MAGNETIC
1
1
FRAME, DRIVE END.........................................1................INCLUDES ITEMS W/#
050@# 1585263240
BUSH
STOPPER
CLUTCH, OVER RUNNING
BOLT
ARMATURE
1
1
1
2
1
1
060@
070@
080@
090@
100@
110@
1983763150
1983763040
1983763320
1983763070
1585263410
1983763080
WASHER, ADJUSTING
YOKE ASSY. .....................................................1................INCLUDES ITEMS W/%
BRUSH
HOLDER, BRUSH ASSY....................................1................INCLUDES ITEMS W/+
120@% 1585263360
130@ 1585263380
2
140@+ 1585263390
150@+ 1585263370
SPRING, BRUSH
BRUSH
3
1
160@
170@$ 1585263250
180@ 1585293310
1983763200
FRAME, END.....................................................1................INCLUDES ITEM W/$
BUSH
SCREW, PAN-HEAD
1
1
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 143
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KUBOTA Z482-EB ENGINE — OIL SWITCH ASSY.
PAGE 144 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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KUBOTA Z482-EB ENGINE — OIL SWITCH ASSY.
OIL SWITCH ASSY.
NO.
010
010
020
PART NO.
PART NAME
SWITCH, OIL.....................................................1................Z482-EB
SWITCH, OIL.....................................................1................Z482-E2B AND Z482-E3B
PLUG .................................................................1................Z482-E2B AND Z482-E3B
QTY.
REMARKS
1584139010
1584139013
1584196020
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 145
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KUBOTA Z482-EB/E2B/E3B ENGINE — WATER FLANGE & THERM. ASSY.
PAGE 146 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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KUBOTA Z482-EB/E2B/E3B ENGINE — WATER FLANGE & THERM. ASSY.
WATER FLANGE AND THERMOSTAT ASSY.
NO.
010
010
PART NO.
1687572700
1687572704
PART NAME
QTY.
REMARKS
COMP. FLANGE, WATER, Z482-EB ..................1................INCLUDES ITEMS W/%
COMP. FLANGE, WATER, Z482-E2B/E3B ........1................INCLUDES ITEMS W/#
020%# 1624173370
PIPE, WATER RETURN
GASKET, WATER FLANGE...............................1................Z482-EB
GASKET, WATER FLANGE...............................1................Z482-E2B AND Z482-E3B
1
030
030
040
050
060
070
080
090
100
110
120
120
1584172922
1584172923
0102350616
0102360650
1685173350
1624173360
1553173010
1584173260
1685173270
0102350622
1554383040
1753883040
BOLT
BOLT
2
4
1
2
1
1
1
2
PIPE, WATER RETURN
BAND, PIPE
THERMOSTAT ASSY.
COVER, THERMOSTAT
GASKET, THERMOSTAT
BOLT
SWITCH, THERMOMETER...............................1................Z482-EB
SWITCH, THERMOMETER...............................1................Z482-E2B AND Z482-E3B
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 147
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KUBOTA Z482-EB/E2B/E3B ENGINE — WATER PUMP ASSY.
PAGE 148 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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KUBOTA Z482-EB/E2B/E3B ENGINE — WATER PUMP ASSY.
WATER PUMP ASSY.
NO.
010
PART NO.
1988373030
PART NAME
WATER PUMP ASSY.........................................1................INCLUDES ITEMS W/@
QTY.
REMARKS
020@ 1585273520
030@ 1585273550
040@ 1548173050
050@ 1988373510
060@ 1585273340
FLANGE, WATER PUMP
BEARING
SEAL ASSY., MECHANICAL
IMPELLER, WATER PUMP................................1................Z482-EB AND Z482-E2B ONLY
PIPE, WATER RETURN
1
1
1
1
070
070
080
090
1588173432
1687173430
0102350622
0102350638
GASKET, WATER PUMP NA.............................1................Z482-EB AND Z482-E2B
GASKET, WATER PUMP NA.............................1................Z482-E3B
BOLT
BOLT
4
1
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 149
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KUBOTA Z482-EB/E2B/E3B ENGINE — WATER PIPE ASSY.
PAGE 150 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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KUBOTA Z482-EB/E2B/E3B ENGINE — WATER PIPE ASSY.
WATER PIPE ASSY.
NO.
010
020
030
040
050
050
PART NO.
PART NAME
PIPE, WATER
PIPE, WATER
STUD
QTY.
REMARKS
1584172860
1588172870
1584191510
0275150060
0931889030
1584172960
1
1
1
1
NUT, FLANGE
CLAMP, HOSE...................................................2................Z482-EB
BAND, PIPE.......................................................2................Z482-E2B AND Z482-E3B
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 151
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KUBOTA Z482-EB/E2B/E3B ENGINE — FAN ASSY.
PAGE 152 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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KUBOTA Z482-EB/E2B/E3B ENGINE — FAN ASSY.
FAN ASSY.
NO.
010
020
030
PART NO.
PART NAME
FAN
PULLEY, FAN
BOLT, FLANGE
QTY.
REMARKS
1586774112
1584174250
0175450610
1
1
4
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 153
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KUBOTA Z482-EB/E2B/E3B ENG. — VALVE AND ROCKER ARM ASSY.
PAGE 154 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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KUBOTA Z482-EB/E2B/E3B ENG. — VALVE AND ROCKER ARM ASSY.
VALVE AND ROCKER ARM ASSY.
NO.
010
020
030
040
050
060
070
080
080
090
100
110
120
120
130
PART NO.
PART NAME
VALVE, INLET
VALVE, EXHAUST
SPRING, VALVE
RETAINER, SPRING
COLLET, VALVE SPRING SET
CAP, VALVE
QTY.
REMARKS
1460113110
1460113120
1460113240
1460113330
1460113360
1685113280
1584113150
1584114263
1584114264
1687114430
1584194022
0102350610
1584114350
1G95814350
1460114410
2
2
4
4
4
4
4
SEAL, VALVE STEM
SHAFT, ROCKER ARM .....................................1................Z482-EB AND Z482-E2B
SHAFT, ROCKER ARM .....................................1................Z482-E3B
WASHER
WASHER, FLAT
BOLT
BRACKET, ROCKER ARM ................................2................Z482-EB
BRACKET, ROCKER ARM ................................2................Z482-E2B AND Z482-E3B
STUD .................................................................2................Z482-EB
2
2
2
130A 0175450640
BOLT FLANGE...................................................2................Z482-E2B AND Z482-E3B
NUT....................................................................2................Z482-EB ONLY
WASHER, FLAT.................................................2................Z482-EB ONLY
WASHER, LOCK................................................2................Z482-EB ONLY
140
150
160
170
180
180
190
0205650060
0401250060
0451260060
0541100420
1460114310
1460114312
1584114030
PIN, SPRING
1
SPRING, ROCKER ARM...................................1................Z482-EB AND Z482-E2B
SPRING, ROCKER ARM...................................1................Z482-E3B
ROCKER ARM ASSY.........................................4................INCLUDES ITEMS W/#
200# 1584114230
210# 1460114240
SCREW, ADJUSTING
NUT
4
4
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 155
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KUBOTA Z482-EB/E2B/E3B ENGINE — INLET MANIFOLD ASSY.
PAGE 156 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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KUBOTA Z482-EB/E2B/E3B ENGINE — INLET MANIFOLD ASSY.
INLET MANIFOLD ASSY.
NO.
010
PART NO.
1584111770
PART NAME
QTY.
REMARKS
MANIFOLD, INLET ASSY., Z482-EB.................1................INCLUDES ITEMS W/%
MANIFOLD, INLET ASSY., Z482-E2B/E3B .......1................INCLUDES ITEMS W/#
PIPE BREATHER...............................................1................Z482-E2B AND Z482-E3B
GASKET, IN-MANIFOLD
BOLT
BOLT
010A 1G95711771
015# 1G96005550
020%# 1584111820
030
040
1
2
1
0102350618
0102350645
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 157
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KUBOTA Z482-EB/E2B/E3B ENGINE — EXHAUST MANIFOLD ASSY.
PAGE 158 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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KUBOTA Z482-EB/E2B/E3B ENGINE — EXHAUST MANIFOLD ASSY.
EXHAUST MANIFOLD ASSY.
NO.
010
020
030
040
050
060
070
PART NO.
PART NAME
MANIFOLD, EXHAUST
GASKET
BOLT, UBS
STUD
NUT, UBS
STUD
GASKET, MUFFLER
QTY.
REMARKS
1584112313
1584112360
0175950616
0151350618
0275650060
0151350822
1526312370
1
1
2
2
2
4
1
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 159
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KUBOTA Z482-EB/E2B/E3B ENG. — GLOW PLUG/LAMP AND TIMER ASSY.
PAGE 160 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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KUBOTA Z482-EB/E2B/E3B ENG. — GLOW PLUG/LAMP AND TIMER ASSY.
GLOW PLUG/LAMP AND TIMER ASSY.
NO.
010
PART NO.
1569465990
PART NAME
TIMER, GLOW LAMP
QTY.
1
REMARKS
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 161
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KUBOTA Z482-EB/E2B/E3B ENGINE — STARTER SWITCH ASSY.
PAGE 162 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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KUBOTA Z482-EB/E2B/E3B ENGINE — STARTER SWITCH ASSY.
STARTER SWITCH ASSY.
NO.
010
PART NO.
3741059110
PART NAME
STARTER SWITCH ASSY..................................1................INCLUDES ITEMS W/%
QTY.
REMARKS
020% 3741055180
030% 6641655170
040% 3741055150
CAP, STARTER SWITCH
WASHER
KEY, STARTER
1
1
1
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 163
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KUBOTA Z482-EB/E2B/E3B ENGINE — AIR CLEANER ASSY.
PAGE 164 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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KUBOTA Z482-EB/E2B/E3B ENGINE — AIR CLEANER ASSY.
AIR CLEANER ASSY.
NO.
010
PART NO.
1556211010
PART NAME
AIR CLEANER ASSY.........................................1................INCLUDES ITEMS W/@
QTY.
REMARKS
020@ 155451115
030@ 1558911160
040@ 1522111410
050@ 1522192620
060@ 1556211080
070@# 1522787480
080@# 1522194430
BODY, AIR CLEANER
COVER, AIR CLEANER
COVER, BAFFLE
BOLT, WING
1
1
1
1
ELEMENT, AIR CLEANER ASSY. .....................1................INCLUDES ITEMS W/#
LABEL, ELEMENT A/C
WASHER, WITH RUBBER
BAND, AIR CLEANER
1
1
1
090
100
3415013960
3415013970
CUSHION ..........................................................1................Z482-EB ONLY
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 165
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KUBOTA Z482-EB/E2B/E3B ENGINE — ACCESSORIES
PAGE 166 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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KUBOTA Z482-EB/E2B/E3B ENGINE — ACCESSORIES
ACCESSORIES
NO.
010
020
030
PART NO.
PART NAME
EMERGENCY UNIT
QTY.
REMARKS
1747260604
1584464600
0966180400
1
COMP. REGULATOR .........................................1................REPLACES P/N 1518164602
TUBE FUEL. 8X13X400L
TUBE FUEL. 8X13X240L
TUBE FUEL. 4X8X320L
CLIP, PIPE
1
1
1
4
6
030A 0966180240
040
050
060
0966140320
1491142750
1497142750
CLIP, PIPE
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 167
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KUBOTA Z482-EB/E2B/E3B ENGINE — PISTON KIT (OPTION)
PAGE 168 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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KUBOTA Z482-EB/E2B/E3B ENGINE — PISTON KIT (OPTION)
PISTON KIT (OPTION)
NO.
010
PART NO.
1685321002
PART NAME
KIT, PISTON, Z482-E2B/E3B.............................1................INCLUDES ITEMS W/%
QTY.
REMARKS
020% 1685121114
030% 1685321050
040% 1526121330
050% 1685103312
PISTON
1
1
1
1
ASSY. PISTON RING
CIRCULAR CLIP PISTON PIN
GASKET, CYLINDER HEAD
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 169
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TERMS AND CONDITIONS OF SALE — PARTS
5. Parts must be in new and resalable
condition, in the original Multiquip
package (if any), and with Multiquip part
numbers clearly marked.
Multiquip reserves the right to quote and
sell direct to Government agencies, and to
Original Equipment Manufacturer accounts
who use our products as integral parts of their
own products.
PAYMENT TERMS
Terms of payment for parts are net 30 days.
FREIGHT POLICY
6. The following items are not returnable:
All parts orders will be shipped collect or
prepaid with the charges added to the invoice.
All shipments are F.O.B. point of origin.
Multiquip’s responsibility ceases when a
signed manifest has been obtained from the
carrier, and any claim for shortage or damage
must be settled between the consignee and
the carrier.
a. Obsolete parts. (If an item is in the
price book and shows as being
replaced by another item, it is
obsolete.)
SPECIAL EXPEDITING SERVICE
A $35.00 surcharge will be added to the
invoice for special handling including bus
shipments, insured parcel post or in cases
where Multiquip must personally deliver the
parts to the carrier.
b. Any parts with a limited shelf life
(such as gaskets, seals, “O” rings,
and other rubber parts) that were
purchased more than six months
prior to the return date.
LIMITATIONS OF SELLER’S LIABILITY
MINIMUM ORDER
Multiquip shall not be liable hereunder for
damages in excess of the purchase price of
the item with respect to which damages are
claimed, and in no event shall Multiquip be
liable for loss of profit or good will or for any
other special, consequential or incidental
damages.
The minimum charge for orders from Multiquip
is $15.00 net. Customers will be asked for
instructions regarding handling of orders not
meeting this requirement.
c. Any line item with an extended
dealer net price of less than
$5.00.
d. Special order items.
RETURNED GOODS POLICY
e. Electrical components.
f. Paint, chemicals, and lubricants.
g. Decals and paper products.
h. Items purchased in kits.
Return shipments will be accepted and
credit will be allowed, subject to the following
provisions:
LIMITATION OF WARRANTIES
No warranties, express or implied, are
made in connection with the sale of parts or
trade accessories nor as to any engine not
manufactured by Multiquip. Such warranties
made in connection with the sale of new,
complete units are made exclusively by a
statement of warranty packaged with such
units, and Multiquip neither assumes nor
authorizes any person to assume for it
any other obligation or liability whatever in
connection with the sale of its products. Apart
from such written statement of warranty,
there are no warranties, express, implied or
statutory, which extend beyond the description
of the products on the face hereof.
1. A Returned Material Authorization
must be approved by Multiquip prior to
shipment.
7. The sender will be notified of any material
received that is not acceptable.
8. Such material will be held for five
working days from notification, pending
instructions. If a reply is not received
within five days, the material will be
returned to the sender at his expense.
2. To obtain a Return Material Authorization,
a list must be provided to Multiquip
Parts Sales that defines item numbers,
quantities, and descriptions of the items
to be returned.
9. Credit on returned parts will be issued
at dealer net price at time of the original
purchase, less a 15% restocking
charge.
a. The parts numbers and descriptions
must match the current parts price
list.
b. The list must be typed or computer
generated.
10. In cases where an item is accepted, for
which the original purchase document
can not be determined, the price will be
based on the list price that was effective
twelve months prior to the RMA date.
c. The list must state the reason(s)
for the return.
Effective: February 22, 2006
d. The list must reference the sales
order(s) or invoice(s) under
which the items were originally
purchased.
11. Credit issued will be applied to future
purchases only.
PRICING AND REBATES
e. The list must include the name
and phone number of the person
requesting the RMA.
Prices are subject to change without prior
notice. Price changes are effective on a
specific date and all orders received on or
after that date will be billed at the revised price.
Rebates for price declines and added charges
for price increases will not be made for stock
on hand at the time of any price change.
3. AcopyoftheReturnMaterialAuthorization
must accompany the return shipment.
4. Freight is at the sender’s expense. All
parts must be returned freight prepaid to
Multiquip’s designated receiving point.
PAGE 170 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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NOTES
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 171
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OPERATION AND PARTS MANUAL
HERE’S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL
NUMBER ON-HAND WHEN CALLING
UNITED STATES
Multiquip Corporate Office
MQ Parts Department
18910 Wilmington Ave.
Carson, CA 90746
Contact: [email protected]
Tel. (800) 421-1244
Fax (800) 537-3927
800-427-1244
310-537-3700
Fax: 800-672-7877
Fax: 310-637-3284
Service Department
Warranty Department
800-421-1244
310-537-3700
Fax: 310-537-4259
Fax: 310-943-2238
800-421-1244
310-537-3700
Fax: 310-943-2249
Technical Assistance
800-478-1244
MEXICO
UNITED KINGDOM
MQ Cipsa
Multiquip (UK) Limited Head Office
Carr. Fed. Mexico-Puebla KM 126.5
Momoxpan, Cholula, Puebla 72760 Mexico
Contact: [email protected]
Tel: (52) 222-225-9900
Unit 2, Northpoint Industrial Estate, Tel: 0161 339 2223
Fax: (52) 222-285-0420 Globe Lane,
Dukinfield, Cheshire SK16 4UJ
Contact: [email protected]
Fax: 0161 339 3226
CANADA
Multiquip
4110 Industriel Boul.
Laval, Quebec, Canada H7L 6V3
Contact: [email protected]
Tel: (450) 625-2244
Tel: (877) 963-4411
Fax: (450) 625-8664
© COPYRIGHT 2011, MULTIQUIP INC.
Multiquip Inc and the MQ logo are registered trademarks of Multiquip Inc. and may not be used, reproduced, or altered without written permission. All other trademarks are the property
of their respective owners and used with permission.
This manual MUST accompany the equipment at all times.This manual is considered a permanent part of the equipment and should remain with the unit if resold.
The information and specifications included in this publication were in effect at the time of approval for printing. Illustrations, descriptions, references and technical data contained in
this manual are for guidance only and may not be considered as binding. Multiquip Inc. reserves the right to discontinue or change specifications, design or the information published
in this publication at any time without notice and without incurring any obligations.
Your Local Dealer is:
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