6973GH-22-Q-00003_Attachment_4_DA7000 Series Rev5 manual.pdf

OPERATION AND PARTS MANUAL

THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

To fi nd the latest revision of this publication, visit our website at:

www.multiquip.com

MODELS

DA7000SS-DA7000SSA

DA700SSW-DA7000WGH

PORTABLE GENERATORS

(KUBOTA Z482 SERIES DIESEL ENGINES)

Revision #5 (01/20/11)

PAGE 2 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)

Diesel engine exhaust and some of

PROPOSITION 65 WARNING

DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 3

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.

REPORTING SAFETY DEFECTS

PAGE 4 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)

TABLE OF CONTENTS

DA7000 SERIES GENERATOR

Proposition 65 Warning Reporting Safety Defects Table Of Contents Parts Ordering Procedures Safety Information ..................................................... 6-11 Specifi cations (Generator) Specifi cations (Engine) Dimensions Installation ............................................................... 16-17 General Information Components (Generator) ......................................... 19-20 Components (Engine) Load Applications Inspection/Setup ...................................................... 23-27 Operation ................................................................. 28-30 Shutdown Preparation For Long Term Storage Maintenance ............................................................ 32-35 Maintenance (Trailer) ............................................... 36-37 Trailer Guidelines ..................................................... 38-51 Trailer Wiring Digram Generator Wiring Digram Engine Wiring Digram Troubleshooting (Engine and Generator) ................ 55-56 Troubleshooting (Engine) ......................................... 57-58 Explanation Of Code In Remarks Column Suggested Spare Parts

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 Muffl er Assembly ..................................................... 76-77 Fuel Tank Assembly ................................................. 78-79 Oil Filter Retrofi t Assembly ...................................... 80-81 Enclosure Assembly ................................................ 82-85 Rubber Seals Assembly .......................................... 86-87

KUBOTA Z482-EB/E2B/E3B Die-sel Engines 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 NOTICE

Specifi cations and part numbers are subject to change without notice.

DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 5

PARTS ORDERING PROCEDURES

w w w .m u lt iq u ip

.c o m

Ordering parts has never been easier!

Choose from three easy options:

WE ACCEPT ALL MAJOR CREDIT CARDS!

When ordering parts, please supply:

❒ Dealer Account Number ❒ Dealer Name and Address ❒ Shipping Address (if different than billing address) ❒ Return Fax Number ❒ Applicable Model Number ❒ Quantity, Part Number and Description of Each Part

❒ Specify Preferred Method of Shipment:

✓ UPS/Fed Ex ✓ DHL

■ Priority One ✓ Truck

■ Ground

■ Next Day

■ Second/Third Day

If you have an MQ Account, to obtain a Username and Password, E-mail us at: parts@multiquip.

com.

To obtain an MQ Account, contact your District Sales Manager for more information.

Order via Internet (Dealers Only):

Order parts on-line using Multiquip’s SmartEquip website!

■ View Parts Diagrams

■ Order Parts

■ Print Specification Information

Note: Discounts Are Subject To Change

Goto www.multiquip.com and click on Order Parts to log in and save!

Use the internet and qualify for a 5% 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)

Fax your order in and qualify for a 2% Discount on Standard orders for all orders which include complete part numbers.*

Order via Phone: Domestic (US) Dealers Call:

1-800-427-1244

Best Deal!

International Customers should contact their local Multiquip Representatives for Parts Ordering information.

Non-Dealer Customers:

Contact your local Multiquip Dealer for parts or call 800-427-1244 for help in locating a dealer near you.

Note: Discounts Are Subject To Change

Effective:

January 1st, 2006

NOTICE

All orders are treated as Standard Orders and will ship the same day if received prior to 3PM PST.

PAGE 6 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)

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.

SAFETY MESSAGES

The four safety messages shown below will inform you about potential hazards that could injure you or others. The safety messages specifi cally 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.

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.

DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 7

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.

NEVER operate this equipment when not feeling well due to fatigue, illness or when under medication.

NEVER operate this equipment under the infl uence of drugs or alcohol.

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.

NOTICE

This equipment should only be operated by trained and qualifi ed personnel 18 years of age and older.

Whenever necessary, replace nameplate, operation and safety decals when they become diffi cult read.

Manufacturer does not assume responsibility for any accident due to equipment modifi cations. Unauthorized equipment modifi cation will void all warranties.

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.

ALWAYS know the location of the nearest fi re extinguisher.

ALWAYS know the location of the nearest fi rst 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 fi re department. This information will be invaluable in the case of an emergency.

GENERATOR SAFETY

DANGER

NEVER operate the equipment in an explosive atmosphere or near combustible materials. An explosion or fi re could result causing severe bodily harm or even death.

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.

CAUTION

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

PAGE 8 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)

ENGINE SAFETY

DANGER

The engine fuel exhaust gases contain poisonous carbon monoxide. This gas is colorless and odorless, and can cause death if inhaled.

The engine of this equipment requires an adequate free fl ow of cooling air. NEVER operate this equipment in any enclosed or narrow area where free fl ow of the air is restricted. If the air fl ow is restricted it will cause injury to people and property and serious damage to the equipment or engine.

WARNING

DO NOT place hands or fingers inside engine compartment when engine is running.

NEVER operate the engine with heat shields or guards removed.

Keep fi ngers, hands hair and clothing away from all moving parts to prevent injury.

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.

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, muffl er or cylinder. Allow these parts to cool before servicing equipment.

NOTICE

NEVER run engine without an air fi lter or with a dirty air fi lter. Severe engine damage may occur. Service air fi lter frequently to prevent engine malfunction.

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.

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 suffi cient 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.

In order for a diesel engine to operate at peak effi ciency, 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.

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.

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 fl ames from the engine exhaust. Spark arresters are qualifi ed 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.

DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 9

FUEL SAFETY

DANGER

DO NOT start the engine near spilled fuel or combustible fl uids. Diesel fuel is extremely fl ammable and its vapors can cause an explosion if ignited.

ALWAYS refuel in a well-ventilated area, away from sparks and open fl ames.

ALWAYS use extreme caution when working with fl ammable liquids.

DO NOT fi ll the fuel tank while the engine is running or hot.

DO NOT overfi ll tank, since spilled fuel could ignite if it comes into contact with hot engine parts or sparks from the ignition system.

Store fuel in appropriate containers, in well-ventilated areas and away from sparks and fl ames.

NEVER use fuel as a cleaning agent.

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.

TOWING SAFETY

CAUTION

Check with your local county or state safety towing regulations, in addition to meeting Department of Transportation (DOT) Safety Towing Regulations, before towing your generator.

Refer to MQ Power trailer manual for additional safety information.

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.

ALWAYS shutdown engine before transporting

Make sure the hitch and coupling of the towing vehicle are rated equal to, or greater than the trailer “gross vehicle weight rating.”

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 infl ated to 50 psi cold.

Also check the tire tread wear on both vehicles.

ALWAYS make sure the trailer is equipped with a safety chain.

ALWAYS properly attach trailer’s safety chains to towing vehicle.

ALWAYS make sure the vehicle and trailer directional, backup, brake and trailer lights are connected and working properly.

DOT Requirements include the following:

• Connect and test electric brake operation.

• Secure portable power cables in cable tray with tie wraps.

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.

Avoid sudden stops and starts. This can cause skidding, or jack-knifi ng. Smooth, gradual starts and stops will improve towing.

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.

Place chock blocks underneath wheel to prevent rolling while parked.

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.

PAGE 10 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)

ELECTRICAL SAFETY

DANGER

DO NOT touch output terminals during operation. Contact with output terminals during operation can cause electrocution, electrical shock or burn.

The electrical voltage required to operate the generator can cause severe 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.

NEVER insert any objects into the output receptacles during operation. This is extremely dangerous. The possibility exists of electrical shock, electrocution or death.

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.

Make sure power cables are securely connected to the generator’s output receptacles. Incorrect connections may cause electrical shock and damage to the generator.

NOTICE

ALWAYS make certain that proper power or extension cord has been selected for the job. See Cable Selection Chart in this manual.

Grounding Safety

DANGER

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 use gas piping as an electrical ground.

DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 11

BATTERY SAFETY

DANGER

DO NOT drop the battery. There is a possibility that the battery will explode.

DO NOT expose the battery to open fl ames, sparks, cigarettes, etc. The battery contains combustible gases and liquids. If these gases and liquids come into contact with a fl ame or spark, an explosion could occur.

WARNING

ALWAYS wear safety glasses when handling 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 environment to avoid the risk of a dangerous concentration 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.

ENVIRONMENTAL SAFETY

NOTICE

Dispose of hazardous waste properly.

Examples of potentially hazardous waste are used motor oil, fuel and fuel fi lters.

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.

PAGE 12 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)

SPECIFICATIONS (GENERATOR)

Table 1. Specifi cations (Generator)

AC Generator 60 Hz AC Power Source

Model DA7000SS/DA7000SSA

DA7000SSW/DA7000SSWGH

Type 2-Pole Brushless Revolving Field Type Excitation Solid State, Statically Excited System Speed 3,600 RPM Cooling System Self-Ventilation Max Power Output 7 kW Continuous Power Output 6 kW Rated Voltage 120/240V

Current Max/Continuous (120V) 58.3/50 amps

Current Max/Continuous (240V) 29.2/25 amps Phase Single Phase (4 wire) Frequency 60 Hz 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 specifi cations quoted herein are subject to change without prior notice.

DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 13

Table 2. Specifi cations (Engine)

Engine

Kubota Engine Model Z482-EB Z482-E2B-DGDE-2 Z482-E3B-DGDE-2 Tier 1 2 4 Gen. Enclosure Color Orange Orange/White White Type Vertical, water-cooled, 4-cycle diesel engine

Bore X Stroke 2.64 in. X 2.68 in.

(67 mm x 68 mm.)

Displacement 29.23 cu.-in. (479 cm3) Number of Cylinders 2 Max Output 12.5~13.9 H.P./3600 R.P.M.

Fuel #2 Diesel Fuel Fuel Capacity 6.6 gal. (25 liters) Fuel Consumption .7 gals. (2.63 liters)/hr.

Coolant Capacity 2.95 quarts (2.8 liters) Lube Oil Capacity 2.64 quarts (2.5 liters) Oil Alert System Yes Starting Method Electric Start

Battery 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)

SPECIFICATIONS (ENGINE)

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).

PAGE 14 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)

DIMENSIONS

Figure 1. Dimensions

DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 15

NOTE

PAGE 16 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)

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).

GROUND ROD

FOR EARTH

GROUND

GENERATOR

GROUND LUG

CONNECT TO

BUILDING

GROUND

IF REQUIRED

8 FT. MINIMUM

REFERENCE

NEC 250-52(C)

GROUND

CABLE

#8 MINIMUM

GROUND

S-1123

WHISPERWATT 7000TM

GROUND ROD

FOR EARTH

GROUND

GENERATOR

GROUND

LUG

CONNECT TO

BUILDING

GROUND

(OPTION)

8 FT. MINIMUM

REFERENCE

NEC 250-52(C)

DANGER

THE POSSIBILITY EXISTS OF IF

GENERATOR/WELDER IS NOT PROPERLY GROUNDED.

ALWAYS CONNECT EARTH GROUND (GROUND

ROD) TO GENERATOR G.F.C.I. GROUND TERMINAL.

ELECTROCUTION

G.F.C.I

GROUND

STUD

GROUND

CABLE

#8 MINIMUM

FOR FURTHER GROUNDING

INSTRUCTIONS, READ MANUAL

D93110000

Figure 2. Generator Grounding

DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 17

INSTALLATION

OUTDOOR INSTALLATION

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.

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.

Foreign materials such as dust, sand, lint and abrasive materials have a tendency to cause excessive wear to engine and alternator parts.

INDOOR INSTALLATION

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.

PLACEMENT

The generator should always be placed on a fl at level surface when it is running. DO NOT place the generator on slopes, the possibility exists that the generator could slide.

WARNING

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

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.

GENERATOR GROUNDING

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 specifi es that the cable ground shall be connected to the grounding system of the building as close to the point of cable entry as practical.

NEC articles 250-64(b) and 250-66 set the following grounding requirements:

1. Use one of the following wire types to connect the generator to earth ground.

a. Copper - 8 AWG (5.3 mm2)

b. Aluminum - 6 AWG (8.4 mm2)

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.

3. NEC article 250-52(c) specifi es that the earth ground rod should be buried a minimum of 8 ft. into the ground.

NOTICE

When connecting the generator to any buildings electrical system ALWAYS consult with a licensed electrician.

DANGER

Before connecting this generator to any building’s electrical system, a licensed electrician must install an isolation (transfer) switch.

Serious injury or death may result without this transfer switch.

PAGE 18 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)

GENERAL INFORMATION

FAMILIARIZATION

Generator

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.

Control Panel

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

Main Circuit Breaker 265V @25 Amps

GFCI Circuit Breaker 120V @20 Amps

Idle Control Switch

Starter Switch

Warning Lamp Unit

Hour Meter

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.

Battery Charge Alarm

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.

Water Temperature Alarm

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.

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.

Idle Control Switch

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.

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.

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.

Excitation System

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).

Excitation current is sourced from the battery to the excitation windinding in the stator. Current applied to this coil creates a magnetic fi eld. The rotating armature is induced with AC current.

Engine

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 specifi cations.

In keeping with Multiquip's policy of constantly improving its products, the specifi cations quoted herein are subject to change without prior notice.

Figure 3 and Figure 4 show the basic controls and indicators for the DA7000 series generators.

DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 19

COMPONENTS (GENERATOR)

Figure 3. Generator Components

1. Fuel Gauge — Indicates the amount of fuel in the fuel tank.

2. Air Outlet Exhaust — Allows engine exhaust to exit the generator into the open air. NEVER block this opening.

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.

4. Lifting Hook — Use this hook to lift the generator.

5. Engine Air Cleaner — Prevents dirt and other debris from entering the fuel system. Lift locking latch on air fi lter cannister to gain access to fi lter element.

6. Overfl ow Bottle — Supplies coolant to the radiator when radiator coolant level is low. Fill to indicated level as shown on bottle.

7. Engine Oil Filler Port — Remove this cap to add engine oil. Use only recommended type oil. See Table 5.

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.

10. Automatic Speed Control Solenoid — Automatically regulates engine speed.

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).

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.

13. Air Inlet Vent — Allows outside air to enter the generator. NEVER block this opening.

14. Battery — Provides +12 VDC power for the generator.

When replacing battery (12V 35 AH) use only recommended type battery.

15. Ground Terminal — Use this terminal to connect external equipment grounds so that the GFCI receptacle will have a ground path.

16. Fuel Tank — Holds 6.6 gallons (25 liters) of diesel fuel.

PAGE 20 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)

Figure 4. Generator Components

17. Fuel drain Plug — Remove this plug to drain fuel from the fuel tank.

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.

19. CS6369 Receptacle — Dual voltage receptacle, provides 120/240 volts output at 25 amps.

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.

22. Receptacle G.F.C.I. — This receptacle provides 120 volts output at 20 amps.

23. GFCI Circuit Breaker — This single pole circuit breaker provides circuit protection (120V @20 amps) for the G.F.C.I receptacle.

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 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.

28. Warning Lamp Display — Lights red when the following conditions occur:

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.

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.

29. Starter Switch — With key inserted turn clockwise to start engine.

30. Oil Filter — Provides oil fi ltering for the engine.

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.

COMPONENTS (GENERATOR)

DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 21

COMPONENTS (ENGINE)

Figure 5. Kubota Z482 Series

INITIAL SERVICING

The engine (Figure 5) must be checked for proper lubrication and fi lled with fuel prior to operation. Refer to the manufacturer's engine manual for instructions and details of operation and servicing.

1. Water Drain Cock — Open this cock to drain water

2. Fuel Filter — Prevents dirt and other debris from entering the fuel system. Replace fi lter as recommended in the maintenance section of this manual.

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. Refi ll or replace with recommended type oil as listed in Table 5.

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.

7. Air Filter — Prevents dirt and other debris from entering the fuel system. Loosen clips on side of air fi lter cannister to gain access to fi lter element. Replace with only manufactures recommended type air cleaner.

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.

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.

10. Oil Drain Plug/Crankcase — Remove to drain crankcase oil. Fill with recommended type oil as listed in Table 5. Crankcase holds a maximum of 2.64 quarts (2.5 liters) of motor oil.

11. Starter — Starts engine when ignition key is rotated to the "ON" position

12. Oil Filter — Spin-on type, fi lters oil contaminants.

Replace fi lter as recommended in the maintenance section of this manual.

13. Oil Pressure Switch — Monitors engine oil pressure.

In the event of low oil pressure engine will shutdown.

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.

PAGE 22 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)

Single Phase Load — 60 Hz

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.

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 infl uenced by the effi ciency, power factor and starting system of the equipment.

WATTS = VOLTAGE x AMPERAGE

The power factor of this generators is 1.0 See Table 3 below when connecting loads.

NOTICE

If wattage is not given on the equipment's name plate, approximate wattage may be determined by multiplying nameplate voltage by the nameplate amperage

Table 3. Power Factor By Load Type Of Load Power Factor

Single-phase induction motors 0.4 - 0.75 Electric heaters, incandescent lamps 1.0

Fluorescent lamps, mercury lamps 0.4 - 0.9

Electronic devices, communication equipment 1.0

Common power tools 0.8

NOTICE

When using a combination of dual receptacles, total load should not exceed the rated capacity of the generator.

NOTICE

When connecting power tools or equipment pay close attention to the required starting current capacity.

LOAD APPLICATIONS

To determine the running wattage for your load, multiply the running wattage as indicated by steps 1, 2, and 3 below:

1. INCANDESCENT LOADS

Lights, heaters and similar appliances.

total the running wattage and multiply by 1.

Example:

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:

A 1 inch drill runs at 1 kW use a 2 kW generator

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.

Extension Cables

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.

NOTICE

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.

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.

DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 23

INSPECTION/SETUP

GENERAL INSPECTION PRIOR TO OPERATION

Ground Power Tools

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.

Figure 6. Ground Pin

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.

Circuit Breakers

ALWAYS place the main, and GFCI circuit breakers in the OFF position prior to starting the engine.

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.

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!

Table 4. Table 4. Cable Selection (60 Hz, Single Phase Operation) Cable Selection (60 Hz, Single Phase Operation)

Current In Amperes

Load In Watts Maximum Allowable Cable Length 120 Volts 240 Volts #10 Wire #12 Wire #14 Wire #16 Wire

2.5 300 600 1000 ft. 600 ft. 375 ft. 250 ft.

5 600 1200 500 ft. 300 ft. 200 ft. 125 ft.

7.5 900 1800 350 ft. 200 ft. 125 ft. 100 ft.

10 1200 2400 250 ft. 150 ft. 100 ft.

15 1800 3600 150 ft. 100 ft. 65 ft.

20 2400 4800 125 ft. 75 ft. 50 ft.

CAUTION: Equipment damage can result from low voltage.

PAGE 24 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)

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 fi lter for dirt and dust. If air fi lter is dirty, replace air fi lter 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 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.

Figure 8. Engine Oil Dipstick

4. If the oil level is low, remove the oil fi ller cap (Figure 9) and fi ll 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).

Figure 9. Engine Oil Filler Port

Table 5. Oil Type Temperature Oil Type

Above 77° F (25° C) SAE 30 or SAE10W-30

SAE 15W-40

32°~ 77° F (0° ~ 25° C)

SAE 20 or SAE10W-30

SAE 15W-40

Below 32° F (0° C) SAE 10 or SAE10W-30

SAE 15W-40

DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 25

Fuel Check

Fill the fuel tank with #2 diesel fuel. DO NOT fi ll the tank beyond capacity.

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 fi lling. Handle fuel in a safety container. If the container does not have a spout, use a funnel.

1. Read the fuel gauge located on top of the generator (Figure 10) to determin if the fuel level is low.

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.

Figure 11. Adding Fuel

NOTICE

When adding engine oil DO NOT overfi ll.

DANGER

Motor fuels are highly fl ammable 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.

INSPECTION/SETUP

Coolant (Antifreeze)

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

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.

Operation Freezing Weather

When operating in freezing weather, be certain the proper amount of antifreeze (Table 7) has been added.

NOTICE

When refueling, be sure to use a strainer for fi ltration.

DO NOT top-off fuel. DO NOT fi ll the tank beyond capacity. Wipe up any spilled fuel immediately!

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

Table 6. Coolant Capacity Engine and Radiator .74 gal (2.8 liters) Reserve Tank (Full) .23 gal (.87 liters)

Table 7. Anti-Freeze Operating Temperatures

Vol % Anti-Freeze

Freezing Point

°C °F

50 -37 -34

PAGE 26 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)

CLEANING THE RADIATOR

The engine may overheat if the radiator fi ns become overloaded with dust or debris. Periodically clean the radiator fi ns with compressed air. Cleaning inside the machine is dangerous, so clean only with the engine turned off and the negative battery terminal disconnected.

AIR CLEANER

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 insuffi cient charging of the battery. Inspect the fan belt for damage and wear and adjust it in accordance with the Kubota Engine Owner's Manual.

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.

Figure 12. Fan Belt Tension

NOTICE

When the antifreeze is mixed with water, the antifreeze mixing ratio must be less than 50%.

CAUTION

NEVER place hands near the belts or fan while the generator set is running.

BATTERY

This unit is of negative ground DO NOT connect in reverse.

Always maintain battery fl uid level between the specifi ed marks. Battery life will be shortened, if the fl uid level are not properly maintained. Add only distilled water when replenishment is necessary.

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.

The battery is suffi ciently charged if the specifi c gravity of the battery fl uid is 1.28 (at 68° F). If the specifi c gravity should fall to 1.245 or lower, it indicates that the battery is dead and needs to be recharged or replaced.

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.

Figure 13. Battery Connections

CAUTION

ALWAYS disconnect the negative terminal FIRST and reconnect negative terminal LAST.

DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 27

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.

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…