OPERATION AND PARTS MANUAL
MODELS
DA7000SS-DA7000SSA
DA700SSW-DA7000WGH
PORTABLE GENERATORS
(KUBOTA Z482 SERIES DIESEL ENGINES)
Revision #5 (01/20/11)
To fi nd the latest revision of this
publication, visit our website at:
www.multiquip.com
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.
PROPOSITION 65 WARNING
Diesel engine exhaust and some of
PAGE 2 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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 1-888327-4236 (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
TABLE OF CONTENTS
DA7000 SERIES GENERATOR
Proposition 65 Warning .................................................. 2
Reporting Safety Defects ................................................ 3
Table Of Contents ........................................................... 4
Parts Ordering Procedures ............................................. 5
Safety Information .....................................................6-11
Specifi cations (Generator) ............................................ 12
Specifi cations (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
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
NOTICE
KUBOTA Z482-EB/E2B/E3B Diesel 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
Air Cleaner Assembly ....................................... 164-165
Accessories ......................................................... 166-167
Piston Kit (Option) ...............................................168-169
Terms and Conditions Of Sale — Parts ...................... 170
-163
Specifi cations and part numbers are subject to change
without notice.
PAGE 4 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
PARTS ORDERING PROCEDURES
r
Ordering parts has never been easier!
Choose from three easy options:
January 1
Effective:
st
, 2006
Best Deal!
Order via Internet (Dealers Only):
Order parts on-line using Multiquip’s SmartEquip website!
■ View Parts Diagrams
■ Order Parts
■ Print Specification Information
Goto www.multiquip.com and click on
Order Parts
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)
Non-Dealer Customers:
Contact your local Multiquip Dealer for
parts or call 800-427-1244 for help in
locating a dealer near you.
to log in and save!
Order via Phone:
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 you
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.*
Fax your order in and qualify for a 2% Discount
on Standard orders for all orders which include
complete part numbers.*
Domestic (US) Dealers Call:
1-800-427-1244
International Customers should contact
their local Multiquip Representatives for
Parts Ordering information.
Note: Discounts Are Subject To Change
Note: Discounts Are Subject To Change
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
NOTICE
All orders are treated as Standard Orders and will
ship the same day if received prior to 3PM PST.
❒ Specify Preferred Method of Shipment:
✓ UPS/Fed Ex ✓ DHL
■ Priority One ✓ Tr uck
■ Ground
■ Next Day
■ Second/Third Day
www.multiquip.com
WE ACCEPT ALL MAJOR CREDIT CARDS!
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 5
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
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.
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)
SAFETY INFORMATION
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.
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
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 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
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 7
SAFETY INFORMATION
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.
PAGE 8 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
SAFETY INFORMATION
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.
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 9
SAFETY INFORMATION
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.
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.
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)
SAFETY INFORMATION
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.
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.
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.
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 11
SPECIFICATIONS (GENERATOR)
Table 1. Specifi cations (Generator)
AC Generator
60 Hz AC Power Source
Battery
Dimensions
(L x W x H)
Dry Net Weight
Model
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
DA7000SS/DA7000SSA
DA7000SSW/DA7000SSWGH
12V -35Ah
25.6 x 44.9 X 31.3 in.
(650 X 1,140 X 795 mm)
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.
PAGE 12 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
SPECIFICATIONS (ENGINE)
Table 2. Specifi cations (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
Engine
Dimensions
(L x W x H)
Dry Net Weight
Bore X Stroke
Displacement 29.23 cu.-in. (479 cm
2.64 in. X 2.68 in.
(67 mm x 68 mm.)
3
)
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
13.82 x 15.31 X 20.47 in.
(351 X 389 X 520 mm)
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
DIMENSIONS
Figure 1. Dimensions
PAGE 14 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
NOTE
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 15
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).
INSTALLATION
THE POSSIBILITY EXISTS OF IF
GENERATOR/WELDERIS NOT PROPERLY GROUNDED.
ALWAYSCONNECT EARTH GROUND (GROUND
ROD) TO GENERATORG.F.C.I. GROUNDTERMINAL.
GROUND
CABLE
#8MINIMUM
G.F.C.I
GROUND
STUD
FORFURTHER GROUNDING
INSTRUCTIONS,READ MANUAL
ELECTROCUTION
G
E
N
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E
R
R
O
A
TO
U
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REFERENCE
NEC250-52(C)
8FT. MINIMUM
GROUNDROD
FOREARTH
GROUND
CONNECTTO
BUILDING
D93110000
GROUND
(OPTION)
GENERATOR
GROUND LUG
DANGER
M
WHISPERWATT 7000
GROUND
S
1
1
2
3
T
GROUND ROD
GROUND
CABLE
FOR EARTH
GROUND
#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)
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.
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
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.
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.
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.
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.
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 17
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
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.
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.
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 watercooled, 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.
PAGE 18 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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.
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.
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
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.
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.
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.
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
PAGE 20 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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 (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.
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 21
LOAD APPLICATIONS
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.
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
WATTS = VOLTAGE x AMPERAGE
The power factor of this generators is 1.0 See Table 3 below
when connecting loads.
Table 3. Power Factor By Load
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.
Type Of Load Power Factor
Single-phase induction motors 0.4 - 0.75
Electric heaters, incandescent
lamps
Fluorescent lamps, mercury
lamps
Electronic devices,
communication equipment
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.
1.0
0.4 - 0.9
1.0
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.
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
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.
PAGE 22 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
GENERAL INSPECTION PRIOR TO OPERATION
Table 4.
Cable Selection (60 Hz, Single Phase 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.
INSPECTION/SETUP
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.
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.
Current In
Amperes
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.
Load In Watts Maximum Allowable Cable Length
120 Volts 240 Volts #10 Wire #12 Wire #14 Wire #16 Wire
Cable Selection (60 Hz, Single Phase Operation)
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 23
INSPECTION/SETUP
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.
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
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.
Temperature Oil Type
Above 77° F (25° C)
32°~ 77° F
(0° ~ 25° C)
Below 32° F (0° C)
SAE 30 or SAE10W-30
SAE 15W-40
SAE 20 or SAE10W-30
SAE 15W-40
SAE 10 or SAE10W-30
SAE 15W-40
Figure 8. Engine Oil Dipstick
PAGE 24 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
INSPECTION/SETUP
NOTICE
When adding engine oil DO NOT overfi ll.
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.
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!
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
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
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 11. Adding Fuel
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.
Table 6. Coolant Capacity
Engine and Radiator .74 gal (2.8 liters)
Reserve Tank (Full) .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
Vol %
Anti-Freeze
50 -37 -34
Freezing Point
°C °F
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 25
INSPECTION/SETUP
NOTICE
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 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.
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
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
CAUTION
NEVER place hands near the belts or fan
while the generator set is running.
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.
CAUTION
ALWAYS disconnect the negative terminal FIRST and
reconnect negative terminal LAST.
Figure 13. Battery Connections
PAGE 26 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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.
INSPECTION/SETUP
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
OPERATION
Before Starting the Engine
CAUTION
The engine’s exhaust contains harmful emissions.
ALWAYS have adequate ventilation when operating.
Direct exhaust away from nearby personnel.
WARNING
NEVER manually start the engine with the main or GFCI
circuit breakers in the ON (closed) position.
1. Open the cabinet door and turn the fuel cock lever
(Figure 14) to the “ON” position.
3. NEVER start the engine with the main circuit breaker
in the ON position. Always place circuit breaker (Figure 16)
in the OFF position before starting.
OFF OFF
25A
25A
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.
Figure 17. GFCI Circuit Breaker (OFF)
Figure 14. Fuel Cock Lever (ON)
2. NEVER operate the generator with the doors open
(Figure 15). Operation with the doors open may cause
insuffi cient cooling of the unit, and engine damage may
result. Close the doors for normal operation.
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Figure 15. Generator Doors
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 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.
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)
OPERATION
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).
6. Let the engine idle for fi ve minutes with the Idle Control
Switch (Figure 19) placed in the ON position.
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.
2. Place GFCI circuit breaker (Figure 21) in the ON
position.
Figure 21. GFCI Circuit Breaker (ON)
3. Read voltmeter on front panel of generator (Figure 22)
and verify that 120 VAC 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.
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 Verifi cation
1. Place main circuit breaker (Figure 20) in the ON
position.
ON ON
25A
Figure 20. Main Circuit Breaker (ON)
25A
Figure 22. 120V GFCI/L5-30R Receptacles
NOTICE
When using a combination of dual receptacles, total
load should not exceed the rated capacity of the
generator.
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 29
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..
Figure 23. 120/240 CS-6369 Receptacle
Stopping the Engine (Normal Shutdown)
1. Place main circuit breaker (Figure 25) in the OFF
position.
OFF 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.
25A
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 24. 120/240V L14-30R Receptacle
6. Connecting of loads (power tools, lighting ect.) to the
generator receptacles can now be done.
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
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)
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 refi ll
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
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
DESCRIPTION
(3)
Engine Oil
Oil Filter
Cartridge
Air Cleaner
Element
All Nuts & Bolts
Cooling Fins CHECK X
Fuel Tank CLEAN X
Fuel Filter CLEAN X
Fuel Filter
Element
Fuel lines CHANGE Every 2 years, replace if necessary (2)
Battery CHANGE X
Radiator Hoses/
Clamps
Radiator
Coolant
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
profi cient. Refer to the KUBOTA Shop Manual for service procedures.
(3) For commercial use, log hours of operation to determine proper maintenance intervals.
OPERATION DAILY
CHECK X
CHANGE X X
CHANGE X
CHECK X
CHANGE X(1)
RETIGHTEN IF
NECESSARY
CHANGE X
CHANGE Every 2 years, replace if necessary (2)
CHANGE X
X
FIRST
MONTH OR
50 HRS.
EVERY 3
MONTHS
OR 25 HRS.
EVERY 6
MONTHS
OR 50 HRS.
EVERY
YEAR OR
100 HRS.
EVERY
2 YEARS
OR
200 HRS.
EVERY 8
YEARS
800 HRS.
OR
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..
PAGE 32 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
MAINTENANCE
Maintenance
Perform the scheduled maintenance procedures as defi ned
by Table 8 and below:
Engine Oil
Every 100 hours: Change engine oil after the fi rst 50 hours
of operation and 100 hours thereafter. Always check the
crankcase oil level prior to each use, or when the fuel tank
is fi lled. Insuffi cient 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.
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
specifi ed in Table 5. Crankcase oil capacity is 2.64 qts.
(2.5 liters).
2. Screw on new oil fi lter by hand until seal contacts the
fi lter mounting base. Install drain bolt with sealing
washer and hand tighten.
NOTICE
When installing the oil fi lter, coat rubber seal with a
small amount of lubricant (motor oil). DO NOT over-
tighten cartridge. Hand tighten only.
3. Replace engine oil with recommended type oil as listed
in Table 5. For engine oil capacity, see Table 2 (engine
specifi cations). Fill to upper limit as shown in Figure 8.
Engine Air Cleaner
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
Every 200 hours: Replace the engine oil fi lter cartridge
after every 200 hours of operation.
1. Clean oil fi lter mounting base, and coat oil fi lter seal
(Figure 30) with clean engine oil.
Figure 30. Oil Filter Cartridge
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 33
remove all dust and debris that may have accumulated
inside air cleaner body.
3. Tap the edge of element lightly to allow heavy dust
build-up to fall off.
4. Tap the paper fi lter 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 fi lter element from from the inside while turning
the element. NEVER brush off dirt. Brushing will force
dirt into the fi bers.
5. Replace the fi lter element once a year or every six
cleanings or if it is excessively dirty
MAINTENANCE
Cleaning the Fuel Filter
Every 100 hours: Clean fuel fi lter every 100 hours of
operation or once a month to remove dust or water.
1. Place fuel cock lever (Figure 32) in the close position.
2. Disconnect fuel lines from fuel fi lter.
Figure 32. Fuel Cock Lever (OFF)
Replacing Fuel Filter Element
Radiator
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. 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.
Every 200 hours: Replace fuel fi lter element.
1. Remove the top cap (Figure 33) from the fuel fi lter and
rinse cap and fi lter bowl with diesel fuel.
2. Remove element, and rise with diesel fuel.
3. Reinstall fuel fi lter and connect fuel lines.
Figure 33. Fuel Filter Disassembly
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 overfl ow tank and drain.
COOLANT DRAIN
COOLANT DRAIN
PLUG
OIL DRAIN
4. Inspect all fuel lines every 50 hours.
Figure 35. Coolant Drain Plug
PAGE 34 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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.
3. Check hoses for softening and kinks. Check clamps
for signs of leakage.
4. Tighten coolant drain plug and reinstall the overfl ow
tank.
5. Fill with coolant as recommended by the engine
manufacturer.
6. Close radiator cap tightly.
WARNING
Allow engine to cool when fl ushing out
radiator. Flushing the radiator while hot
could cause serious burns from water or
steam.
RADIATOR CLEANING
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.
Completely drain the oil from the crankcase and refi ll if
necessary with fresh oil.
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.
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.
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 fi ns 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 fi ns and tube.
Figure 36. Radiator Cleaning
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 35
MAINTENANCE (TRAILER)
TRAILER MAINTENANCE
The following trailer maintenance guidelines are intended
to assist the operator in preventive maintenance.
Adjustable Channel
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.
Figure I. Adjustable Channel
Wheel Bearings
Wheel bearings (Figure II) must be inspected and
lubricated once a year or 12,000 miles to insure safe
operation of your trailer.
Follow the steps below to disassemble the wheel hub and
service the wheel bearings. See Figure II.
BEARING
OIL
SEAL
BEARING
CUP
Figure II. Wheel Hub Components
LUG
NUT
WHEEL
HUB
SPINDLE
WASHER
BEARING
CUP
BEARING
COTTER
PIN
DUST
CAP
SPINDLE
NUT
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 fl at 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.
Replace seals that have nicks, tears or wear.
Lubricate the bearings with a high quality EP-2
automotive wheel bearing grease.
Wheel Hub Adjustment
If trailer wheel bearings are immersed in water, they must
be replaced.
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.
DANGER
Turn the hub slowly, by hand, while tightening the spindle
If trailer wheels are under water for a long period of
nut until you can no longer turn the hub by hand.
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
The possibility exists of the wheels falling off causing
spindle nut is loose.
equipment damage and severe bodily harm even death!
Install a new cotter pin through the spindle nut and
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.
axle.
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)
MAINTENANCE (TRAILER)
DANGER
NEVER crawl under the trailer unless it is on fi rm
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!
DANGER
When performing trailer inspection and maintenance
activities, you must jack up the trailer using jacks and
jackstands.
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.
DANGER
Leaf Suspension
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.
AXLE
U-BOLT
HANGER SUPPORT
BRACKET IS WELDED
TO FRAME
LEAF
FRONT
HANGER NUT
FRONT
HANGER BOLT
U-BOLT
LOCKING
NUT
TIE PLATE
Figure III. Leaf Suspension Components
SUSPENSION
Improper weld repair will lead to early failure of the
trailer structure and can cause serious injury or death.
DO NOT repair cracked or broken welds unless you
have a certifi ed welder perform the repair. If not, have
the welds repaired by your dealer.
WARNING
If the trailer is involved in an accident, have it inspected
immediately by qualifi ed personnel. In addition, the
trailer should be inspected annually for signs of wear
or deformations.
DANGER
Worn or broken suspension parts can cause loss of
control, damage to equipment and severe bodily injury,
even death!
Check suspension regularly.
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 37
TRAILER GUIDELINES
The following guidelines are intended to assist the operator
in the operation and handling of a trailer.
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.
COMMON CAUSES FOR LOSS OF TRAILER
Driving too fast for the conditions (maximum speed when
towing a trailer is 55 mph).
Overloading the trailer or loading the trailer unevenly.
Trailer improperly coupled to the hitch.
No braking on trailer.
Not maintaining proper tire pressure.
Not keeping lug nuts tight.
Not properly maintaining the trailer structure.
Shift your automatic transmission into a lower gear for
city driving.
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.
To conserve fuel, don’t use full throttle to climb a hill.
Instead, build speed on the approach.
Slow down for bumps in the road. Take your foot off the
brake when crossing the bump.
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.
DO NOT apply the brakes to correct extreme trailer
swaying. Continued pulling of the trailer, and even slight
acceleration, will provide a stabilizing force.
Ensure machine is towed level to tow vehicle.
TRAILER TOWING GUIDELINES
Recheck the load tiedowns to make sure the load will
not shift during towing.
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.
Use your mirrors to verify that you have room to change
lanes or pull into traffi c.
Use your turn signals well in advance. Allow plenty of
stopping space for your trailer and tow vehicle.
Allow plenty of stopping space for your trailer and tow
vehicle.
DO NOT drive so fast that the trailer begins to sway
due to speed.
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.
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.
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.
Be aware of your trailer height, especially when
approaching roofed areas and around trees.
Make regular stops, about once each hour. Confi rm
that:
• Coupler is secure to the hitch and is locked.
• Electrical connectors are secure.
• There is appropriate slack in the safety chains.
• There is appropriate slack in the breakaway switch
pullpin cable.
• Tires are not visibly low on pressure.
PAGE 38 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
TRAILER GUIDELINES
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.
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.
Check rearview mirrors frequently to observe the trailer
and traffi c.
NEVER drive faster than what is safe.
WARNING
Driving too fast for severe road conditions can result in
loss of control and cause death or serious injury.
Decrease your speed as road, weather, and lighting
conditions deteriorate.
Always check for local trailer tow speed limits in your
area.
WARNING
Do not transport people on the trailer. The transport of
people puts their lives at risk and may be illegal.
COUPLING TO THE TOW VEHICLE
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.
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 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.
• Be sure the hitch components are tight before
coupling the trailer to the tow vehicle.
WARNING
An improperly coupled trailer can result in death or
serious injury.
DO NOT move the trailer until:
• The coupler is secured and locked to hitch.
• The safety chains are secured to the tow vehicle.
• The trailer jack(s) are fully retracted.
DO NOT tow the trailer on the road until:
• Tires and wheels are checked.
• The trailer brakes are checked.
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.
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.
The trailer VIN tag contains the critical safetyinformation
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 39
• The breakaway switch is connected to the tow vehicle.
• The load is secured to the trailer.
• 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.
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.
TRAILER GUIDELINES
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. See Trailer
Wiring Diagram section in this manual.
Standard mirrors usually do not provide adequate visibility
for viewing traffi c to the sides and rear of a towed trailer.
You must provide mirrors that allow you to safely observe
approaching traffi c.
WARNING
Improper electrical connection between the tow vehicle
and the trailer will result in inoperable lights and can
lead to collision.
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.
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.
Drive slowly at fi rst, 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.
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.
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.
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.
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.
TRAILER VIN TAG
Because of the signifi cant 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.
As you did when learning to drive an automobile, fi nd
an open area with little or no traffi c for your fi rst 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.
PAGE 40 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
Figure A below is a sample of the Vehicle Identifi cation
Number (VIN) Tag which is typically located on the left front
of the trailer. See Figure B for location.
Figure A. Vehicle VIN Tag
TRAILER GUIDELINES
To determine the “empty” or “net” weight of your trailer,
weigh it on an axle scale. To fi nd 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.
VIN TAG
TOW VEHICLE
VIN TAG
Figure B. VIN Tag Location
The trailer VIN Tag contains the following critical safety
information for the use of your trailer.
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.
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 Gross Trailer Weight). 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.
PSIC: The tire pressure (psi) measured when cold.
VIN: The Vehicle Identifi cation Number.
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.
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.
SUSPENSION SYSTEM
Sway bars, shock absorbers, heavy duty springs, heavy
duty tires and other suspension components may be
required to suffi ciently tow the trailer and pump.
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.
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 fl asher circuit.
ELECTRICAL CONNECTOR
An Electrical Connector connects the lights on the trailer
to the lights on the towing vehicle.
EMERGENCY FLARES AND TRIANGLE 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 fl ashers 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.
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 41
TRAILER GUIDELINES
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.
JACKSTAND
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.
Ball Hitch Coupler
Pintel Eye Coupler
BALL HITCH COUPLER
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.”
A ball hitch trailer may be fi tted 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.
Check the locking device that secures the coupler to the
ball for proper operation.
If you see or feel evidence of wear, such as fl at 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.
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.
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.
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.
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.
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.
PAGE 42 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
TRAILER GUIDELINES
WARNING
A worn, cracked or corroded hitch ball can fail while
towing and may result in death or serious injury.
Before coupling trailer, inspect the hitch ball for wear,
corrosion and cracks.
Replace worn or damaged hitch ball.
WARNING
A loose hitchball nut can result in uncoupling, leading
to death or serious injury.
Be sure the hitch ball is tight to the hitch before coupling
the trailer.
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.
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.
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.
Coupling the Trailer to the Tow Vehicle (Ball Coupler)
Lubricate the hitch ball and the inside of the coupler with
a thin layer of automotive bearing grease.
Lower the trailer (Figure D) until the coupler fully engages
the hitch ball.
2-INCH
TRAILER
COUPLER
Figure D. Ball Hitch Coupling Mechanism
VEHICLE
2-INCH
BALL
TOW
Engage the coupler locking mechanism. In the engaged
position, the locking mechanism securely holds the
coupler to the hitch ball.
Insert a pin or lock through the hole in the locking
mechanism.
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.
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.
NOTICE
Overloading can damage the tongue jack. DO NOT
use the tongue jack to raise the tow vehicle more than
one inch.
Slowly back up the tow vehicle so that the hitch ball is
near or aligned under the coupler.
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
Using the jackstand at the front of trailer (tongue), turn
continue retracting the jack to its fully retracted position.
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.
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 43
TRAILER GUIDELINES
Attaching Safety Chain
Visually inspect the safety chains and hooks for wear or
damage. Replace worn or damaged safety chains and
hooks before towing.
Attach the safety chains so that they:
• Cross underneath the coupler. See Figure E.
TOW
VEHICLE
TRAILER
TONGUE
SAFETY CHAIN
MASTER LINK
Figure E. Attaching Safety Chain (Ball Hitch)
• 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).
• 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
.
WARNING
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.
• Fasten chains to frame of tow vehicle. DO NOT fasten
chains to any part of the hitch unless the hitch has
holes or loops specifi cally for that purpose.
IMPORTANT!
CROSS BOTH
SAFETY CHAINS
Backup Lights (place tow vehicle gear shift in reverse).
Turn Signals (activate tow vehicle directional signal
lever).
WARNING
Improper electrical connection between the tow vehicle
and the trailer will result in inoperable lights and electric
brakes, and can lead to collision.
Before each tow:
• 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.
Uncoupling the Ball Hitch
Follow these steps to uncouple ball hitch from tow
vehicle:
Block trailer tires to prevent the trailer from rolling, before
jacking the trailer up.
Disconnect the electrical connector.
Disconnect the breakaway brake switch cable. Promptly
replace the pullpin in the switchbox.
Before extending jackstand, make certain the ground
surface below the jackstand foot will support the tongue
load.
Rotate the jackstand handle (or crank) clockwise. This
will slowly extend the jack and transfer the weight of the
trailer tongue to the jack.
• 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).
PAGE 44 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
TRAILER GUIDELINES
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.”
Figure F. Pintle Hitch Coupler
A pintle hitch trailer may be fi tted 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.
If you see or feel evidence of wear, such as fl at 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.
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
Coupler-to-hitch mismatch can result in uncoupling,
leading to death or serious injury.
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.
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.
Pintle Coupler and Pintle Hook
Before each tow, check the locking device that secures the
coupler to the pintle hook assembly.
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.
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.
Before coupling trailer, inspect the pintle hitch hook for
wear, corrosion and cracks.
Replace worn or damaged pintle hitch hook.
Rock the pintle eye coupler to make sure it is secured
tightly to the hitch.
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.
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 45
TRAILER GUIDELINES
H
L
CROSSBO
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.
WARNING
A defective pintle hitch not properly fastened can result
in uncoupling, leading to death or serious injury.
Be sure the pintle hook is securly tighten to the tow
vehicle before coupling the trailer.
Coupling Trailer to Tow Vehicle (Pintle Coupler)
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.
OPEN the pintle hook locking mechanism (Figure G).
Place the hook inside the eye coupler. CLOSE the pintle
hook mechanism.
TRAILER
PINTLE
TOW
VEHICLE
SAFETY
CHAIN
HOOK
IMPORTANT!
Figure G. Attaching Safety Chain (Pintle Hitch)
Insert a pin or lock through the hole in the locking
mechanism.
TONGUE
PINTLE
RING “EYE”
TH
SAFETY C
MASTER
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.
TIRE SAFETY
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.
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.
Uneven tread wear can be caused by tire imbalance, axle
misalignment or incorrect infl ation.
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.
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.
Allow 3 hours cool-down after driving as much as 1 mile at
40 mph before checking tire pressure. Trailer tires will be
infl ated to higher pressures than passenger vehicle tires.
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.
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
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.
PAGE 46 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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.
WARNING
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.
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 fi rst 10, 25 and 50 miles of driving and before
each tow thereafter.
Failure to perform this check can result in a wheel parting
from the trailer and a crash, leading to death or serious
injury.
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 fi rst 10, 25
and 50 miles of driving.
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
This certifi cation/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.
There is a vehicle placard (Figure H) located in the same
location as the certifi cation label described above. This
placard provides tire and loading information. In addition,
this placard will show a statement regarding maximum
cargo capacity.
TIRE AND LOADING INFORMATION
The weight of cargo should never exceed XXX kg. Or XXX lbs.
TIRE
FRONT
REAR
SPARE
SIZE
COLD TIRE PRESSURE
Figure H. Trailer Tire Placard
SEE OWNER’S
MANUAL FOR
ADDITIONAL
INFORMATION
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.
Excessive loads and/or underinfl ation cause tire overloading
and, as a result, abnormal tire fl exing 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 infl ation
is critical. The proper air pressure may be found on the
certifi cation/VIN label and/or on the Tire and Loading
Information placard. This value should never exceed the
maximum cold infl ation pressure stamped on the tire.
Improper tire pressure can result in a blowout and loss
of control, which can lead to death or serious injury.
Be sure tires are infl ated to pressure indicated on side
wall before towing trailer.
Perform the following steps to determine the load limit of
your trailer.
Step 1.
Locate the statement, “The weight of cargo should never
exceed XXX kg or XXX lbs.,” on your vehicle’s Tire and
Determining Load Limit of Trailer
Determining the load limits of a trailer includes more than
Loading Information placard (Figure I). This value equals
the available amount of equipment load capacity.
understanding the load limits of the tires alone. On all
trailers there is a Federal certifi cation/VIN label that is
located on the forward half of the left (road) side of the unit.
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 47
TRAILER GUIDELINES
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’s VIN (Certifi cation) label at the left front of the trailer
(See Figure I).
Determining Load Limit of Tow Vehicle
Step 1.
Locate the statement, “The combined weight of occupants
and cargo should never exceed XXX lbs.,” on your vehicle’s
placard.
Step 2.
Determine the combined weight of the driver and
passengers who will be riding in your vehicle.
Step 3.
Subtract the combined weight of the driver and passengers
from XXX kilograms or XXX pounds.
along with other care and maintenance activities, can
also:
Improve vehicle handling.
Help protect you and others from avoidable breakdowns
and accidents.
Improve fuel economy.
Increase the tire life.
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 fl at
tire or other tire failure.
TIRE FUNDAMENTALS
Federal law requires tire manufacturers to place standardized
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
identifi cation number for safety standard certifi cation and
in case of a recall.
Step 4.
The resulting fi gure equals the available amount of cargo
and luggage capacity. For example, if the “XXX” amount
equals 1400 lbs. and there will be fi ve 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.
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.
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 fl at tires. These actions,
Figure I. Standard Tire Sidewall Information
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.
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.
PAGE 48 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
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.
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 fi nd this information in your
owner’s manual. If not, contact a local tire dealer. Note:
You may not fi nd this information on all tires because it is
not required by law.
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.
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 in Table A. Note: You may
not fi nd this information on all tires because it is not required
by law.
Table A. Speed Rating
Letter Rating Speed Rating
Q 99 mph
R 106 mph
S 112 mph
T 118 mph
U 124 mph
H 130 mph
V 149 mph
W 168* mph
Y 186* mph
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.
Maximum Load Rating: This number indicates the
maximum load in kilograms and pounds that can be carried
by the tire.
Maximum Permissible Infl ation Pressure: This number
is the greatest amount of air pressure that should ever be
put in the tire under normal driving conditions.
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.
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”.
Temperature Letter: This letter indicates a tire’s
resistance to heat. The temperature grade is for a tire that
is infl ated properly and not overloaded. Excessive speed,
underinfl ation 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”.
Refer to Figure J for additional tire information for light
trucks.
U.S. DOT Tire Identifi cation 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.
Tire Ply Composition and Materials Used: The number of
Figure J. UTQGS Tire Information
plies indicates the number of layers of rubber-coated fabric
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 49
TRAILER GUIDELINES
Tires for light trucks have other markings besides those
found on the sidewalls of passenger tires.
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.
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.
Load Range: This information identifi es the tire’s loadcarrying capabilities and its infl ation limits.
Tire Safety Tips
Slow down if you have to go over a pothole or other
object in the road.
DO NOT run over curbs or other foreign objects in the
roadway, and try not to strike the curb when parking.
Check tire infl ation pressure weekly during use to insure
the maximum tire life and tread wear.
DO NOT bleed air from tires when they are hot.
Inspect tires for uneven wear patterns on the tread,
cracks, foreign objects, or other signs of wear or
trauma.
sidewall should not be repaired. Tires must be removed
from the rim to be properly inspected before being plugged
and patched.
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 infl ation 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.
Table B below will help pinpoint the causes and solutions
of tire wear problems.
Table B. Tire Wear Troubleshooting
Wear Pattern Cause Solution
Center Wear Over infl ation.
Edge Wear Under infl ation.
Side Wear
Toe Wear Incorrect toe-in. Align wheels.
Cupping Out-of-balance.
Flat Spots
Loss of camber
or overloading.
Wheel lockup and
tire skidding.
Adjust pressure to particular
load per tire manufacturer.
Adjust pressure to particular
load per tire manufacturer.
Make sure load does not
exceed axle rating.
Align wheels.
Check bearing adjustment
and balance tires.
Avoid sudden stops when
possible and adjust brakes.
Remove bits of glass and foreign objects wedged in
the tread.
Make sure your tire valves have valve caps.
ALWAYS check tire pressure on tow vehicle and trailer
before towing. Check tire pressure at least once a
month.
WARNING
ALWAYS wear safety glasses when
removing or installing force fi tted 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
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)
TRAILER GUIDELINES
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 infl ation 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
Lug nuts are prone to loosen after initial installation,
which can lead to death or serious injury. Check all
wheel lug nuts periodically.
Lug Nut Torque Requirements
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:
1. Start all wheel lug nuts by hand.
3. Check to see if the lug nuts are tight after the fi rst 10,
25 and 50 miles of driving and before each tow
thereafter
Figure K. Wheel Lug Nuts Tightening Sequence
Table C. Tire Torque Requirements
Wheel Size
12" 20-25 35-40 50-65
13" 20-25 35-40 50-65
14" 20-25 50-60 90-120
15" 20-25 50-60 90-120
16" 20-25 50-60 90-120
First Pass
FT-LBS
Second Pass
FT-LBS
Third Pass
FT-LBS
2. Torque all lug nuts in sequence. See Figure K. DO
Lights and Signals
NOT torque the wheel lug nuts all the way down.
Tighten each lug nut in 3 separate passes as defi ned
by Table C.
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.
NOTICE
NEVER use an pneumatic air gun to tighten wheel
lug nuts.
Over-tightening lug nuts will result in breaking the studs
or permanently deforming the mounting stud holes in
Check the wire harness for cuts, fraying or other damage.
If it needs replacing, contact your dealer.
WARNING
Improper operating taillights, stoplights and turn signals
can cause collisions.
the wheels.
Check all lights before each tow.
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 51
TRAILER WIRING DIGRAM
Figure 37. Trailer Wiring Diagram
PAGE 52 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
GENERATOR WIRING DIGRAM
Figure 38. Generator Wiring Diagram (DA7000 SERIES)
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 53
ENGINE WIRING DIGRAM
Figure 39. Engine Wiring Diagram
PAGE 54 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
TROUBLESHOOTING (ENGINE AND GENERATOR)
Table 9. Engine and Generator Troubleshooting
SYMPTOM POSSIBLE PROBLEM SOLUTION
Dead Battery? Replace Battery.
Engine fails to start and
starter does not rotate.
Engine fails to start and
starter rotates.
Engine starts "Idle
Control Switch" is
in OFF position and
engine remains at low
speed.
Engine starts and "Idle
Control Switch" is in
OFF position. Engine
speed rises and no
voltage is present in AC
power source.
Defective Starter Switch? Replace Switch.
Defective Starter? Replace Starter.
Fuse F5 Burned Out? Replace Fuse.
Broken Pre-Heat Circuit?` Check Pre-Heat Circuit.
No Fuel? Add Fuel.
Defective Wiring? Check Wiring.
Defective Idle Control Switch? Replace Switch.
Idle Control Switch is in ON position? Set Switch to OFF Position.
Clogged Fuel Strainer? Clean or Replace.
Clogged Air Cleaner? Clean or Replace.
Defective Idle Control Device? Replace.
Disconnected Wiring? Check and Repair Wiring.
No Voltage Present in AC Power source Replace Rectifi er (RE1).
Defective Rotor? Replace Rotor.
Defective Voltmeter? Replace Voltmeter.
Disconnected Wiring? Check and Repair Wiring.
Layer Short-Circuit in armature winding? Replace Armature.
Engine starts and "Idle
Control Switch" is in
OFF position . Engine
speed rises and AC
power voltage is too low
or cannot be used.
Defective Circuit Breaker (Protector)? Replace Circuit Breaker (Protector).
Layer Short-Circuit, Broken Wires In
Armature Winding?
Repair or Replace Armature.
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 55
TROUBLESHOOTING (ENGINE AND GENERATOR)
Table 9. Engine and Generator Troubleshooting (Continued)
SYMPTOM POSSIBLE PROBLEM SOLUTION
Engine starts and "Idle
Control Switch" is in
OFF position. Engine
speed rises and battery
discharges too soon.
Engine starts and "Idle
Control Switch" is in
OFF position. Engine
speed rises and engine
seems overloaded.
Engine starts and "Idle
Control Switch" is in
OFF position. Engine
speed rises and engine
has large vibrations.
overload.
Engine starts and "Idle
Control Switch" is in
OFF position. Engine
speed rises and engine
has abnormal noise.
Defective Engine Regulator? Replace Regulator.
Defective Wiring? Repair or Replace Wiring.
Defective Alternator? Repair or Replace Alternator.
Damaged Alternator Bearing? Replace Alternator Bearings.
Bad Engine Installation? Repeat Installation of of Engine.
Loose Engine Parts? Check All Engine Parts For Tightnes.
Defective Alternator?
Defective Enclosure? Check Enclosure Bolts for Tightness.
Check Alternator for Damaged Bearing or
Loose Clamping Bolts.
Engine starts and "Idle
Control Switch" is in OFF
position. Engine speed
rises and remains at high
speed when Idle Control
switch is placed in the ON
position.
Defective Idle Control Device? Repair or Replace Idle Control Device.
Defective Idle Control Switch? Replace Idle Control Switch.
Defective Solenoid? Replace Solenoid.
Defective Relay? Replace Relay.
PAGE 56 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
TROUBLESHOOTING (ENGINE)
Table 10. Engine Troubleshooting
SYMPTOM POSSIBLE PROBLEM SOLUTION
No fuel? Replenish fuel.
Air in the fuel system? Bleed system.
Water in the fuel system? Remove water from fuel tank.
Fuel pipe clogged? Clean fuel pipe.
Fuel fi lter clogged? Clean or change fuel fi lter.
Engine does not start.
Starter does not run.
Excessively high viscosity of fuel or
engine oil at low temperature?
Fuel with low cetane number? Use the specifi ed fuel.
Fuel leak due to loose injection pipe
retaining nut?
Incorrect injection timing? Adjust.
Fuel cam shaft worn? Replace.
Injection nozzle clogged? Clean injection nozzle.
Injection pump malfunctioning? Repair or replace.
Seizure of crankshaft, camshaft, piston,
cylinder liner or bearing?
Compression leak from cylinder?
Improper valve timing? Correct or replace timing gear.
Piston ring and liner worn? Replace.
Excessive valve clearance? Adjust.
Battery discharged? Charge battery.
Starter malfunctioning? Repair or replace.
Key switch malfunctioning? Repair or replace.
Use the specifi ed fuel or engine oil.
Tighten nut.
Repair or replace.
Replace head gasket, tighten cylinder
head bolt, glow plug and nozzle holder.
Wiring disconnected? Connect wiring.
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 57
TROUBLESHOOTING (ENGINE)
Table 10. Engine Troubleshooting (Continued)
SYMPTOM POSSIBLE PROBLEM SOLUTION
Fuel fi lter clogged or dirty? Clean or change.
Air cleaner clogged? Clean or change.
Engine revolution is not
smooth
Either white or
blue exhaust gas is
observed.
Either black or dark
gray exhaust gas is
observed.
Fuel leak due to loose injection pipe retaining
nut?
Injection pump malfunctioning? Repair or replace.
Incorrect nozzle opening pressure? Adjust.
Injection nozzle stuck or clogged? Repair or replace.
Fuel over fl ow pipe clogged? Clean.
Governor malfunctioning? Repair.
Excessive engine oil? Reduce to the specifi ed level.
Piston ring and liner worn or stuck? Repair or replace.
Incorrect injection timing? Adjust.
Defi cient compression? Adjust top clearance.
Overload? Lessen the load.
Low grade fuel used? Use the specifi ed fuel.
Fuel fi lter clogged? Clean or change.
Air cleaner clogged? Clean or change.
Defi cient nozzle injection? Repair or replace the nozzle.
Incorrect injection timing? Adjust.
Tighten nut.
Engine's moving parts seem to be seizing? Repair or replace.
Defi cient output.
PAGE 58 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
Uneven fuel injection? Repair or replace the injection pump.
Defi cient nozzle injection? Repair or replace the nozzle.
Compression leak?
Replace head gasket, tighten cylinder head
bolt, glow plug and nozzle holder.
NOTES
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 59
EXPLANATION OF CODE IN REMARKS COLUMN
”
The following section explains the different symbols and
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.
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.
SAMPLE PARTS LIST
NO. PART NO. PART NAME QTY. REMARKS
1 12345 BOLT .....................1 .....INCLUDES ITEMS W/%
2% WASHER, 1/4 IN. ..........NOT SOLD SEPARATELY
2% 12347 WASHER, 3/8 IN. ..1 .....MQ-45T ONLY
3 12348 HOSE ..................A/R ...MAKE LOCALLY
4 12349 BEARING ..............1 .....S/N 2345B AND ABOVE
NO. Column
Unique Symbols — All items with same unique
symbol
QTY. Column
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.
A blank entry generally indicates that the item is not sold
separately. Other entries will be clarifi ed in the “Remarks
Column.
REMARKS Column
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.
Assembly/Kit — All items on the parts list with the
same unique symbol will be included when this item is
purchased.
Indicated by:
“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.
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.
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.
PART NO. Column
Numbers Used — Part numbers can be indicated by a
number, a blank entry, or TBD.
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.
A blank entry generally indicates that the item is not sold
separately or is not sold by Multiquip. Other entries will
be clarifi ed in the “Remarks” Column.
Serial Number Break — Used to list an effective serial
number range where a particular part is used.
Indicated by:
“S/N XXXXX AND BELOW”
“S/N XXXX AND ABOVE”
“S/N XXXX TO S/N XXX”
Specifi c Model Number Use — Indicates that the part
is used only with the specifi c model number or model
number variant listed. It can also be used to show a
part is NOT used on a specifi c model or model number
variant.
Indicated by:
“XXXXX ONLY”
“NOT USED ON XXXX”
“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.
“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.
PAGE 60 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
SUGGESTED SPARE PARTS
DA7000 SERIES GENERATORS WITH KUBOTA
Z482-EB/Z482-E2B/ Z482-E3B DIESEL ENGINES
1 to 3 units
Qty. P/N Description
5............1556211010 ..........AIR FILTER
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
NOTICE
Part numbers on this Suggested Spare Parts list may
supersede/replace the part numbers shown in the
following parts lists.
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 61
25A
ACCIRCUIT
BREAKER
O
FF
2
2
A
120
V
20A
120V
OFF
ON
GA-2.9R
ACCIRCUIT
BREAKER
O
FF
22A
120
V
20A
120V
OFF
ON
GA-2.9R
ACCIRCUIT
BREAKER
OF
F
2
2A
120
V
20A
120V
OFF
ON
GA-2.9R
20A
120V
AC POWER OUTPUT
THEPOSSIBILITY EXISTS OF IF
GENERATOR/WELDERIS NOT PROPERLY GROUNDED.
ALWAYSCONNECT EARTH GROUND (GROUND
ROD)TO GENERATOR G.F.C.I. GROUND TERMINAL.
GROUND
GE
CABLE
NE
G
RO
RA
UN
#8MINIMUM
D
G.F.C.I
GROUND
STUD
FORFURTHER GROUNDING
INSTRUCTIONS,READ MANUAL
Using a generator indoors .CAN KILL YOU IN MINUTES
Generator exhaust contains carbon monoxide. This is
a posion you cannot see or smell
20A
2900
GA-2.9R
F
A
F
2
O
2
ACCIRCUIT
120V
BREAKER
OFF
NEVER use inside a home
or garage, even if doors
and windows are open
Avoid other generator hazards.
26
FUSE PULLY
USE SPECIFIED FUSE ONLY.
F
6
5
F 15A
4
F5A
3
F5A
2
F5A
1
F 30A
16
25A
120V/240V
DANGER
ELECTROCUTION
TO
R
LUG
GROUNDROD
FOREARTH
GROUND
CONNECTTO
BUILDING
GROUND
(OPTION)
8FT.MINIMUM
REFERENCE
NEC250-52(C)
D93110000
DANGER
20A
120
2900
GA-2.9R
F
A
F
2
O
2
ACCIRCUIT
120V
BREAKER
OFF
Only use OUTSIDE and
far away from windows,
doors, and vents.
35
12
20
WARNING
HOT COOLANT can cause
severe burns.
DO NOT remove cap if
radiator is hot.
17
SPARE
Beforeconnecting this generator to any building’s
electricalsystem, a licensed electrician must install
anisolation [transfer] switch.
Seriousinjury or death may result without this
transferswitch.
23
WARNING!
15A
5A
30A
25A
A55200000A
34
22
G.F.C.I.
1
120
2900
GA-2.9R
F
A
F
2
O
2
ACCIRCUIT
120V
BREAKER
OFF
.READ MANUAL BEFORE USE
FUEL DRAIN
FRONT VIEW
COOLING
WATER
S-3061
DCL183
MULTIQUIPWhisperWatt
AC Generator
1. Check the oil level.
2. Check the water level.
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
Warninglamp and the Oil Pressure Warning lamp
shouldbe lit.
7. Turn the key to “HEAT”.When the preheat lamp
lightsturn the key to “START” to start the engine.
AVOIDHIGH SPEEDS IMMEDIATELYAFTER
STARTING.
8.
Whenthe engine starts, the Oil Pressure
Alarmlamp should go out.
WHISPERWATT
7KWAC
Model DA-7000SS
AC
CIRCUIT
BREAKER
7000WAT T
DIESELPOWERED AC GENERATOR
D
9
2
2
0
0
1
0
0
27
G
ROUND
S
1
1
2
3
28
OPERATINGPROCEDURE
IDLE
AC
VOL
TMETER
00
H
O
15
S-3060
9.
Letthe engine idle for more than 5 minutes
withthe Idle Control switch in “ON” position.
10.
Checkthe engine for abnormal vibrations noise
andoil leakage.
11.Turnthe Idle Control switch to either “ON” or
“OFF”for full engine operation.
12.After generating let the engine run for 5 minutes
withthe Idle Control switch in the “ON” position.
NEVERSTOP THE ENGINE SUDDENLYEXCEPT
IN AN EMERGENCY.
13.Stop the engine by turning the key in the
StarterSwitch to “STOP” and remove the key.
ON
RU
N
STOP
OFF
C
ON
TRO
L
0
0
0
H
O
UR
S
STARTER
UR
SWITCH
M
ETE
R
G.F.C.I.
D
9
2
2
0
0
1
0
0
22
DANGER
Donot touch output terminals or
internalwiring while unit is operating.
S
4
ELECTRICAL
9
8
5
Turnoffpower before servicing.
SHOCK
HAZARD
Onlyqualified personnel should
install,use or service this
equipment.
11
NAMEPLATE AND DECALS ASSY.
CAUTION
WATER
COOLANT
LEVEL
H
RESERVE
L
10
TANK
DCL194
8
0
9
0
2
-
S
OIL DRAIN
R
O
N
E
A
T
CAUTION
C
N
LE
E
S
LA
C
M
P
R
E
E
U
L
6
R
0
O
E
4
1
H
-
R
S
E
P
Y100
PA
R
E
V
E
4
S-4984
DANGEROUS
GAS
WARNING
MOVING PARTScan cause
severe injury.
DO NOT operate with
doors open.
Stop engine before
servicing.
TM
WHISPERWATT 7000
COOLANT DRAIN
3
0
4
3
-1
S
2
WARNING
Onlyoperate machine in well ventilated
areas.
DONOT inhale exhaust gases.
Onlyqualified personnel should
install,use or service this
equipment.
DCL182
33
FUEL COCK
ON
5
ON
CAUTION
Before starting the engine, check that the oil
level is within the indicated operating range.
If the level is above the or below
the , it is important to correct before
operating to avoid damage to the engine.
-1
S
HLmark
mark
4
0
4
14
19
CAUTION
HOT PARTScan burn skin.
DO NOT touch until the
machine has sufficiently
cooled.
32
OILLEVEL
DIPSTICK
H
L
DCL181
A555000103
30
HEAT
START
13
GROUND
forG.F.C.I
S
-3
8
2
1
9
MODEL
SERIALNO.
36
DANGER
Cigarettes,flames or sparks could cause battery to explode. Always
shieldeyes and face from battery. Do not charge or use booster cables
oradjust post connections without proper instruction and training.
24
POISON
Containssulfuric acid. Avoid contact with skin, eyes or clothing. In
eventof accident flush with water and call a physician immediately.
6
USE #2 DIESEL
FUEL ONLY
29
CHECK DAILY
1. Maintain water/coolant level
at of radiator coils.
top
2. Maintain reserve tank water/
coolantlevel between H and
Lmark. Use a mixture of
50/50Anti-Freeze/Water.
3. Add coolant when reserve
tankis low (L). Fill to the H
markwith Anti-Freeze/Water.
1
9
0
2
-
S
EXPLOSIVE GASES
KEEP VENT CAPSTIGHT AND LEVEL
CAUSES SEVERE BURNS
KEEP OUT OF REACH OF CHILDREN
S-1408
25
18
DECAL
KIT
8
0
4
-1
S
USE #2 DIESEL
FUELONLY
FUELCOCK
ON
ON
37
COOLING
1
6
0
3
S
WATER
7
CAUTION
DO NOT
OPERATE WITH
DOORS OPEN
31
S-1409
REAR VIEW
PAGE 62 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
NAMEPLATE AND DECALS ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1 0800628504 DECAL: GROUND .............................................1................S1123
2# 1630645004 DECAL: OIL DRAIN ...........................................1................S1403
3# 1630647004 DECAL: COOLANT DRAIN ................................1................S1404
4# 1630610404 DECAL: CAUTION (PAPER ELEMENT) ............1................S1406
5# 1630680104 DECAL: FUEL COCK.........................................1................S1407
6# 1630680004 DECAL: USE 2 DIESEL FUEL ONLY ................1................S1408
6# B9504501204 DECAL: DIESEL FUEL .....................................1................B90450120 — DA7000SSA
7# 1630610504 DECAL: CAUTION (DOORS OPEN) .................2................S1409
8# 0600689404 DECAL: BATTERY POSITIVE ...........................1................S2090
9# 0800689504 DECAL: BATTERY NEGATIVE ..........................1................S2091
10# 6390671104 DECAL: IMPORTANT CHECK DAILY ................1................S2377
11# 7810680104 DECAL: FUEL DRAIN ........................................1................S3060
12# 7810680204 DECAL: COOLING WATER ...............................1................S3061
13# 8700611603 DECAL: GROUND FOR G. F. C. I. .....................1................S3821 REPLACES P/N 7670624004
14# 8700611804 DECAL: WARNING DANGEROUS GAS ...........1................S4984
15# 8700611904 DECAL: DANGER ELECT. SHOCK HAZ. ..........1................S4985
16# A5552000003 DECAL: AC POWER OUTPUT ..........................1................A55200000
16# A5552000013 DECAL: AC POWER OUTPUT ..........................1................A55200001 — DA7000SSA
17# A5552000103 DECAL: OPERATING PROCEDURE ................1................A55200010
17# A5552000113 DECAL: OPERATING PROCEDURE ................1................A55200011 — DA7000SSA
18# B9504000304 DECAL: CAUTION HOT PARTS ........................1................B90400030
19# B9504000404 DECAL: WARNING MOVING PARTS ................2................B90400040
20# B9504100104 DECAL: WARNING HOT COOLANT .................1................B90410010
21# B9504500004 DECAL: WARNING DIESEL FUEL ....................1................B90450000
22# 7670624004 DECAL: G. F. C. I. ..............................................2................D92200100
22# D9522001004 DECAL: G. F. C. I. ..............................................2................D92200100 — DA7000SSA
23# 0820610404 DECAL: WARNING (TRANSFER SWITCH) 1
24# 0820650604 DECAL: DANGER EXPLO GASES (BATT.) 1
25# 8700611524 DECAL: CAUTION OIL LEVEL GAUGE 1
25# B9505000304 DECAL: CAUTION OIL LEVEL GAUGE ............1................B90500030 — DA7000SSA
26# 8700625504 DECAL: FUSE BOX 1
27# A556200004 DECAL: MQ .......................................................1................A56200000
28# A5562100003 DECAL: STRIPE MULTIQUIP ............................1................A56210000
29# A5562100104 DECAL: STRIPE MQ .........................................1................A56210010
30# A5562100204 DECAL: STRIPE MQ .........................................1................A56210020
31# A5562100303 DECAL: STRIPE WHISPERWATT .....................2................A56210030
32# A5562100404 DECAL: STRIPE ................................................1................A56210040
33# A5562100504 DECAL: STRIPE ................................................1................A56210050
34 D9531100004 DECAL: DANGER GROUNDING .......................1................D93110000
35 A9504000014 DECAL: DANGER HAZARDOUS FUMES .........1................A90400001
36 PLATE, SERIAL NO. ..........................................1................CONTACT MQ PARTS DEPT.
............................................................................ ...............WITH MODEL AND S/N
37 DCLDA7000SS KIT, DECAL ........................................................1................INCLUDES ITEMS W/#
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 63
GENERATOR ASSY.
PAGE 64 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
GENERATOR ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1 A5110100003 ROTOR ASSY. ...................................................1................INCLUDES ITEMS W/#
1-1# A5116000103 FIELD ASSY. 1
1-2# 7871025004 RECTIFIER ASSY. 2
1-3# 042006304 BEARING 6304 DOU .........................................1................REPLACES 0071206304
1-4# A5113100002 FAN 1
1-5# 0171707033 KEY 1
1-6# 1991072004 SET WASHER FAN 1
1-7# 0012308020 HEX HEAD BOLT 1
2 011208025 HEX HEAD BOLT ...............................................5................REPLACES 0012308025
3 A515510002 END BRACKET 1
4 A5136000103 ARMATURE ASSY. 1
5 A6155000002C END BRACKET .................................................1................REPLACES A6155000002
6 7871329514 GROMMET 1
7 7901316004 SET BOLT 4
8 0040008000 WASHER, LOCK 4
9 031108160 WASHER, FLAT .................................................4................REPLACES 0041206000
10 A6155400104C COVER ..............................................................1................REPLACES A6155400104
11 0027106012 MACHINE SCREW 3
11 0027105012 MACHINE SCREW ............................................3................DA7000SSA
12 0012308020 HEX HEAD BOLT 6
13 0805084704 RUBBER SUSPENSION 2
14 020108060 HEX NUT ...........................................................2................REPLACES 0207006000
14A 0801086104 WASHER, FLAT 2
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 65
CONTROL PANEL ASSY.
PAGE 66 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
CONTROL PANEL ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1 A5225000303 CONTROL PANEL 1
1 A5511302402 CONTROL PANEL .............................................1................DA7000SSA
2 0021805020 MACHINE SCREW 4
3 0601800258 AC VOLTMETER, 120/240 1
4 0207003000 HEX NUT 2
5 0601807456 CIRCUIT BREAKER, KM52 265V 25A 1
6 4341817004 BRACKET CIRCUIT BREAKER 1
7 0021004016 MACHINE SCREW 2
8 0601830771 IDLE CONTROL SWITCH 1
9 1628663602 STARTER SWITCH ...........................................1................REPLACES 0602100077
9A 3741055150 IGNITION, KEY
10 0601810523 INDICATOR ASSY. 1
10A 0601810830 BULB 4
11 0601800682 HOUR METER 820114 1
12 0027403512 MACHINE SCREW 2
12A 0030003500 HEX NUT 2
13 0601811034 RECEPTACLE CS6369 125 250V 50A ..............1................REPLACES 0601812566
14 0601812529 RECEPTACLE, L14- 30R 125V 30A 1
15 0601811031 RECEPTACLE, L5-30R 125V 30A .....................1................REPLACES 0601811035
16 0601812597 RECEPTACLE, 5-20R 120V 20A ......................1................REPLACES 0601812598
17 0021004010 MACHINE SCREW 8
17A 0030004000 HEX NUT ...........................................................8................REPLACES 0207004000
18 0601806420 CIRCUIT PROTECTOR, AC 250V 20A 1
19 0027103005 MACHINE SCREW 2
20 0601815109 GROUND TERMINAL 1
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 67
ELECTRIC PARTS ASSY.
PAGE 68 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
ELECTRIC PARTS ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1 A5262500203 BRACKET ELECTRIC PARTS 1
2 0016906016 HEX HEAD BOLT 4
3 0601842463 RESISTOR, 30W 10 OHM 1
4 0027104012 MACHINE SCREW 2
5 0601823204 RECTIFIER, S5VB60 2
6 0027103020 MACHINE SCREW 2
7 0601823754 RELAY 1
8 0027105016 MACHINE SCREW 1
9 1569465990 LAMP TIMER .....................................................1................REPLACES 0602201273
10 0017105016 HEX HEAD BOLT 1
11 1747260604 EMERGENCY UNIT ..........................................1................REPLACES 0602200475
12 0017105025 HEX HEAD BOLT 4
13 0601815731 TERMINAL BOARD 1
14 0601815759 TERMINAL BOARD 1
15 0027105020 MACHINE SCREW 4
16 8701899004 FUSE BOX 1
16A 0601806642 FUSE, 5A 4
16B 0601806643 FUSE, 15A 2
16C 0601806644 FUSE, 30A 2
17 0027105020 MACHINE SCREW 2
18 0601827350 CONTROL UNIT 1
19 0027104010 MACHINE SCREW 2
20 1584464600 REGULATOR .....................................................1................REPLACES 1584464601
21 0017105025 HEX HEAD BOLT 2
22 16226361032 ROTARY SOLENOID .........................................1................REPLACES 1620150404
23 1992636004 ARM SOLENOID 1
24 0050403020 SPRING PIN 1
25 16226361032 HEX HEAD BOLT ...............................................1................REPLACES 0010106025
25A 0030006000 HEX NUT ...........................................................1................REPLACES 0030006000
26 0207206000 HEX NUT 2
27 D235630004 GOVERNOR ROD 1
28 031108160 WASHER, FLAT .................................................1................REPLACES 0041608000
29 0605010503 SNAP PIN 1
30 0042806000 WASHER, FLAT 1
31 505015300 SNAP PIN ..........................................................1................REPLACES 0605010502
32 0010108050 HEX HEAD BOLT 1
33A 020108060 HEX NUT ...........................................................1................REPLACES 0207008000
33 0601806640 FUSE, 65A 1
34 A5485500004 GUIDE 1
35 0016906016 HEX HEAD BOLT 2
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 69
ENGINE AND RADIATOR ASSY.
PAGE 70 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
ENGINE AND RADIATOR ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1 A5925200004 ENGINE, Z482EB ........................ 1 ........DA7000SS
1 A5924200004 ENGINE, Z482E2BDGDE2 ..........1 ........DA7000SS
1 A5924200094 ENGINE, Z482E3BDGDE2 ..........1 ........DA7000SSA
1A 1980572531 FAN BELT ..................................... 1 ........REPLACES P/N 0602011477
1-1 7000015241 CARTRIDGE OIL FILTER ............ 1 ........REPLACES P/N's 1584132430 AND 0602041271
1-1 1585332435 CARTRIDGE OIL FILTER ............ 1 ........Z482-E3B ENGINE
2 8745112003 ENGINE FOOT 2
3 0012410020 HEX HEAD BOLT 8
4 7085419004 RUBBER SUSPENSION 2
5 0207010000 HEX NUT 2
6 0602012750 RADIATOR ...................................1 ........INCLUDES ITEM W/#
6 0602012795 RADIATOR ................................... 1 ........INCLUDES ITEM W/% DA7000SSA
6-1# 0602011074 CAP RADIATOR 1
6-1% 0602011079 CAP RADIATOR ........................... 1 ........DA7000SSA
7 8702014004 INSULATOR .................................2 ........DA7000SS-DA7000SSW ONLY
8 0605000460 RUBBER MOUNT 2
9 D2312500103 RADIATOR HOSE 1
10 D2312500003 RADIATOR HOSE 1
11 0605515111 HOSE BAND, Ø34 2
11 0605515134 HOSE BAND HS-16 ..................... 2 ........DA7000SSA
12 0605515003 HOSE BAND, Ø30 2
13 1556211010 FILTER AIR CLEANER ASSY. ..... 1 ........REPLACES P/N 0602046265
13A 7000011221 ELEMENT AIR CLEANER ...........1 ........REPLACES P/N's 0602046374, 1556211081
14 3415013960 BAND 1
14A 0222600340 RUBBER CUSHION 1
15 0016908030 HEX HEAD BOLT 1
16 0207008000 HEX NUT 1
17 8742031004 BRACKET AIR CLEANER 1
18 0016908020 HEX HEAD BOLT 2
19 0016906016 HEX HEAD BOLT 2
20 8742032003 HOSE AIR CLEANER 1
21 1612036203 HOSE AIR CLEANER 1
22 0605515006 HOSE BAND, Ø50 1
23 0605515021 HOSE BAND, Ø55 2
24 1622014103 DRAIN JOINT WATER 1
25 1502025103 DRAIN JOINT OIL 1
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
ENGINE AND RADIATOR ASSY.
PAGE 72 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
ENGINE AND RADIATOR ASSY.
NO. PART NO. PART NAME QTY. REMARKS
26 0802011104 PLUG 2
27 0150000018 O-RING A P18 2
28 0016906016 HEX HEAD BOLT 4
29 D2322400004 HOSE JOINT 1
30 0199900550 DRAIN HOSE 1
31 0199900700 DRAIN HOSE 1
31 0199900500 DRAIN HOSE .....................................................1................DA7000SSA
32 0605515094 HOSE BAND, Ø12 4
33 0805010004 DRAIN JOINT 1
34 1552053004 JOINT BOLT 1
35 0602021190 PACKING SW22 2
36 0192200400 DRAIN HOSE 1
37 0605515081 HOSE BAND 1
38 0605515003 HOSE BAND, Ø27 1
38 0605515159 HOSE BAND, Ø32 .............................................1................DA7000SSA
39 0802081403 RESERVE TANK 1
40 0602081104 CAP RESERVE TANK 1
41 1622082104 BRACKET RESERVE TANK 1
42 0016906025 HEX HEAD BOLT 1
43 0016906016 HEX HEAD BOLT 2
44 7222016304 HOSE 1
45 0199900650 HOSE 1
45 0199900650 HOSE .................................................................1................DA7000SSA
46 0605515094 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
BATTERY ASSY.
PAGE 74 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
BATTERY ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1 0167103820 BATTERY 1
2 1702202104 BATTERY SHEET 1
3 D2345200004 BATTERY BAND 1
4 0805082704 BATTERY BOLT 2
5 0037806000 WING NUT 2
6 0040006000 WASHER, LOCK 2
7 0041206000 WASHER, FLAT 2
8 0602220310 TERMINAL ASSY. (POSITIVE) 1
9 0602220311 TERMINAL ASSY. (NEGATIVE) 1
10 0602220600 TERMINAL CAP 1
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 75
MUFFLER ASSY.
PAGE 76 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
MUFFLER ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1 D2332100003 MUFFLER 1
2 0016908020 HEX. HEAD BOLT 4
3 D2335000003 EXHAUST PIPE 1
4 1526312371 GASKET ............................................................1................REPLACES 1526312371
5 1502336004 GASKET 1
6 0207008000 HEX. NUT 4
7 0016908035 HEX. HEAD BOLT 2
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 77
FUEL TANK ASSY.
PAGE 78 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
FUEL TANK ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1 D2365000013 FUEL TANK 1
1A 0810105800 CAP, FUEL TANK 1
1B 0810105900 FUEL FILTER 1
2 0602125033 FUEL GAUGE 1
3 D2365200004 TANK BAND 2
4 0805003414 PAD, TANK BANK 4
5 0016906016 HEX. HEAD BOLT 2
6 0207308000 HEX. NUT 2
7 D1490600104 RUBBER SEAL 1
8 1615511204 RUBBER SEAL 1
8 B9312400004A RUBBER SEAL .................................. 1 ..................DA7000SSA
9 7812014003 DRAIN JOINT 1
10 0802011104 PLUG 1
11 0150000018 O-RING A P18 1
12 0016906016 HEX. HEAD BOLT 2
13 0199900670 DRAIN HOSE 1
14 0605515094 HOSE BAND F-12 2
15 1553143010 FUEL FILTER ASSY. .......................... 1 .................. REPLACES 0602042460 AND 1553143012
15A 1523143560 ELEMENT, FUEL FILTER .................. 1 .................. REPLACES 0602042171 AND 1523143563
16 D2368700004 BRACKET, FUEL FILTER 1
17 0016906016 HEX. HEAD BOLT 2
18 0016908065 HEX. HEAD BOLT 1
19 0966180240 SUCTION HOSE ................................ 1 .................. REPLACES 0605513158
20 0966180400 SUCTION HOSE ................................ 1 .................. REPLACES 0605513101
21 0966140320 RETURN HOSE ................................. 1 .................. REPLACES 0605514101
22 0966140240 RETURN HOSE ................................. 1 .................. REPLACES 0605514102
23 1491142750 HOSE BAND ...................................... 4 .................. REPLACES 0605515070
24 1024442320 HOSE BAND ...................................... 4 .................. REPLACES 0605515072
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 79
WHISPERWATT
7K
W
A
C
M
odelD
A
-7000SS
A
C
A
C
C
IR
CU
IT
B
R
E
A
K
E
R
7000WATT
DIESELPOWERED AC GENERATOR
20A
25A
120V
OIL FILTER RETROFIT ASSY.
O
N
R
U
N
S
T
O
P
H
E
A
T
O
F
F
ID
L
E
C
O
N
T
R
O
L
V
O
L
T
M
E
T
E
R
S
T
A
RT
00
0
0
0
H
O
UR
S
STARTERSWITCH
H
O
U
R
M
E
T
E
R
25A
25A
120/240V
PART OF
ENCLOSURE
15
13
10
12
9
8
7
6
4
3
ENGINE
PAGE 80 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
OIL FILTER RETROFIT ASSY.
NO. PART NO. PART NAME QTY. REMARKS
3 148002003 ADAPTER FILTER 1
4 010601000 HOSE KIT 1
6 149149001 BRACKET ................................. 1 ............... INCLUDES ITEMS W/#
7# BOLT ......................................... 4 ............... NOT SOLD SEPARATELY
8# LOCKWASHER ......................... 4 ............... NOT SOLD SEPARATELY
9 DA7000NUT NUT 3
10 DA7000LOCKWASHER LOCKWASHER 3
12 DA7000BOLT BOLT 3
13 149002000 FILTERHEAD 1
15 7000015241 SPIN-ON OIL FILTER 1
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 81
ENCLOSURE ASSY.
PAGE 82 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
ENCLOSURE ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1 A5415000202 BASE ........................................................1 ...............SEE ORDER CODE CHART BELOW
1A D2492100004 LINING 1
2 D2415100004 FLOOR PANEL .........................................1 ...............SEE ORDER CODE CHART BELOW
3 0016906016 HEX HEAD BOLT 4
4 A5415600104 DUCT ........................................................1 ...............SEE ORDER CODE CHART BELOW
5 0016906016 HEX HEAD BOLT 4
6 D2455200113 SPLASHER PANEL ..................................1 ...............SEE ORDER CODE CHART BELOW
7 D2455200003A SPLASHER PANEL ..................................1 ...............REPLACES P/N D2455200003
....................................................................................SEE ORDER CODE CHART BELOW
8 0016906016 HEX HEAD BOLT 12
9 D2425000012B FRONT FRAME, (ORANGE UNITS) ........1 ...............REPLACES P/N D2425000012
....................................................................................S/N 3757609 AND BELOW
9 D2425000022 FRONT FRAME, (WHITE UNITS) ............1 ...............S/N 3757610 AND ABOVE
9A 0220900340 RUBBER SEAL 2
10 0016906016 HEX HEAD BOLT 3
11 0016908020 HEX HEAD BOLT 2
12 D2312100004 BRACKET RADIATOR 1
13 0016906016 HEX HEAD BOLT 2
14 D2312300013 FAN SHROUD 1
14-1 D2492200004 LINING 1
14-2 0221700050 LINING 4
14-3 0221900165 LINING 4
15 0016906016 HEX HEAD BOLT 4
16 A5435300203 HANGER ...................................................1 ...............SEE ORDER CODE CHART BELOW
17 A5435300403 HANGER ...................................................1 ...............SEE ORDER CODE CHART BELOW
18 0012310025 HEX HEAD BOLT 8
19 D2485500014 HARNESS GUIDE 1
20 0016906016 HEX HEAD BOLT 2
21 A5445000102 REAR FRAME, (ORANGE UNITS) 1
21 A5445000112 REAR FRAME, (WHITE UNITS) 1
22 0016906016 HEX HEAD BOLT 4
23 D2445300004 COVER REAR FRAME .............................1 ...............SEE ORDER CODE CHART BELOW
24 0016906016 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
ENCLOSURE ASSY.
PAGE 84 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
ENCLOSURE ASSY.
NO. PART NO. PART NAME QTY. REMARKS
25 A5465000102 ROOF PANEL, (ORANGE UNITS) 1
25 A5465000112 ROOF PANEL, (WHITE UNITS) 1
26 0016906016 HEX HEAD BOLT 15
27 8432081004 COVER RADIATOR CAP .......................... 1 ...............SEE ORDER CODE CHART BELOW
28 0016906016 HEX HEAD BOLT 2
29 D245500113 SIDE DOOR 1
29A A5495400704 LINING 1
30 D2455000013 SIDE DOOR ..............................................1 ...............SEE ORDER CODE CHART BELOW
30A A5495400704 LINING, (ORANGE UNITS) 1
30A A5495400604 LINING, (WHITE UNITS) 1
31 0605010215 DOOR HANDLE 2
32 0021805016 MACHINE SCREW 8
33 0810014704 PIN 4
34 0080200004 SNAP RING 4
35 D2455700004 DOOR STAY 2
36 7835088004 COLLAR 2
37 0016908020 HEX HEAD BOLT 2
38 A5445200003 REAR DOOR, (ORANGE UNITS) 1
38 A5445200013 REAR DOOR, (WHITE UNITS) 1
39 0601851613 STOPPER 2
40 0810014704 PIN 2
41 0080200004 SNAP RING 2
42 8511864604 TERMINAL PLATE 1
43 0016906016 HEX HEAD BOLT 5
44 0601851660 STOPPER 2
45 97535K25 CAP, 4-INCH FUEL FILL ...........................1 ...............OPTION
46 97535K21 CAP, 3-INCH FUEL GAUGE .....................1 ...............OPTION
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
RUBBER SEALS ASSY.
PAGE 86 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
RUBBER SEALS ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1 0229400470 RUBBER SEAL 4
2 0229400760 RUBBER SEAL 2
3 0222900325 RUBBER SEAL 2
4 0222900125 RUBBER SEAL 4
5 0222600100 RUBBER SEAL 4
6 0228300600 RUBBER SEAL 1
7 0228300200 RUBBER SEAL 2
8 0228300550 RUBBER SEAL 2
9 0227600130 RUBBER SEAL 2
10 0227600500 RUBBER SEAL 2
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 87
KUBOTA Z482-EB/E2B/E3B ENGINE — CRANKCASE ASSY.
PAGE 88 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
KUBOTA Z482-EB/E2B/E3B ENGINE — CRANKCASE ASSY.
CRANKCASE ASSY.
NO. PART NO. PART NAME QTY. REMARKS
010 1685301012 COMP. CRANKCASE, Z482-EB ........................1................INCLUDES ITEMS W/$
010 1685301017 COMP. CRANKCASE, Z482-E2B ......................1................INCLUDES ITEMS W/#
010 1685301019 COMP. CRANKCASE, Z482-E3B ......................1................INCLUDES ITEMS W/%
020$#% 1685196260 CAP, SEALING 3
030$#% 1685196270 CAP, SEALING 3
040$#% 1545196270 CAP, SEALING 2
050$#% 1526196010 PLUG 4
060$#% 1552196020 PLUG 1
070$#% 1552196030 PLUG 1
080$#% 1526196160 PLUG, EXPANSION 1
090$#% 0501200508 PIN, STRAIGHT 2
100$#% 0501200814 PIN, STRAIGHT 2
110$#% 1522133650 PIN, PIPE 1
120$#% 1523133960 PIN, PIPE 2
130$#% 1733159190 PIN, PIPE 2
140$#% 1685116212 COVER, FUEL CAMSHAFT 1
150# 1522133700 O-RING ..............................................................1................Z482-E2B ONLY
160$#% 1584773130 JOINT, DRAIN PIPE 1
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 89
KUBOTA Z482-EB/E2B/E3B ENGINE — OIL PUMP ASSY.
PAGE 90 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
KUBOTA Z482-EB/E2B/E3B ENGINE — OIL PUMP ASSY.
OIL PUMP ASSY.
NO. PART NO. PART NAME QTY. REMARKS
010 1685135010 OIL PUMP ASSY. ...............................................1................Z482-EB
010 1685135012 OIL PUMP ASSY. ...............................................1................Z482-E2B AND Z482-E3B
020 1685135152 GASKET, OIL PUMP NA 1
030 1584191050 BOLT 3
040 1584135660 GEAR, OIL PUMP DRIVE 1
050 0571200408 KEY, FEATHER 1
060 0278350100 NUT, FLANGE 1
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 91
KUBOTA Z482-EB/E2B/E3B ENGINE — OIL PAN ASSY.
PAGE 92 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
KUBOTA Z482-EB/E2B/E3B ENGINE — OIL PAN ASSY.
OIL PAN ASSY.
NO. PART NO. PART NAME QTY. REMARKS
010 1756101505 COMP. OIL PAN 1
020 0112360814 BOLT 1
030 0102350612 BOLT .................................................................14...............Z482-EB AND Z482-E2B
030 0102350614 BOLT .................................................................14...............Z482-E3B
040 1654133750 PLUG, DRAIN 1
050 1545196670 GASKET 1
060 1685132110 FILTER, OIL 1
070 0481400160 O-RING 1
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 93
KUBOTA Z482-EB/E2B/E3B ENG. — CYLINDER HEAD ASSY.
PAGE 94 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
KUBOTA Z482-EB/E2B/E3B ENG. — CYLINDER HEAD ASSY.
CYLINDER HEAD ASSY.
NO. PART NO. PART NAME QTY. REMARKS
010 1522101750 HOOK, ENGINE 2
020 0112360816 BOLT ..................................................................2................Z482-EB
020 0112350816 BOLT ..................................................................2................Z482-E2B AND Z482-E3B
030 1685503042 COMP. CYLINDER HEAD, Z482-EB ..................1................INCLUDES ITEMS W/#
030 1G95703023 COMP. CYLINDER HEAD, Z482-E2B ................1................INCLUDES ITEMS W/%
030 1G68903040 COMP. CYLINDER HEAD, Z482-E3B ................1................INCLUDES ITEMS W/$
040#%$ 1532196260 CAP, SEALING ...................................................1................Z482-EB AND Z482-E3B
045%$ 1526103370 CAP, SEALING ...................................................1................Z482-E2B
050#%$ 1526196010 PLUG 1
060#%$ 1584113540 GUIDE, INLET VALVE 2
070#%$ 1584113560 GUIDE, EXHAUST VALVE 2
080# 1584196020 PLUG .................................................................1................Z482-EB
090 1460103450 BOLT, CYLINDER HEAD 10
100 1685103310 GASKET, CYLINDER HEAD 1
100 1685103312 GASKET, CYLINDER HEAD ..............................1................Z482-EB
110 1522133700 O-RING ..............................................................1................Z482-E2B AND Z482-E3B
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 95
KUBOTA Z482-EB/E2B/E3B ENGINE — GEAR CASE ASSY.
PAGE 96 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
KUBOTA Z482-EB/E2B/E3B ENGINE — GEAR CASE ASSY.
GEAR CASE ASSY.
NO. PART NO. PART NAME QTY. REMARKS
010 1687504024 COMP. CASE, GEAR, Z482EB, Z482E2B .........1................INCLUDES ITEMS W/#
010 1E05104024 COMP. CASE, GEAR, Z482E3B ........................1................INCLUDES ITEMS W/%
020#% 1685196010 PLUG .................................................................2................Z482EB
020#% 1552196030 PLUG .................................................................2................Z482-E2B AND Z482-E3B
030#% 1584156280 PIN, START SPRING 1
040 0481406130 O-RING ..............................................................3................Z482-EB AND Z482-E2B
050 1586204132 GASKET, GEAR CASE .....................................1................Z482-EB AND Z482-E2B
050 1586204130 GASKET, GEAR CASE .....................................1................Z482-E3B
060 0102350618 BOLT 1
070 0102360650 BOLT 8
080 1584191010 BOLT 5
090 0102350670 BOLT ..................................................................1................Z482EB
090 0102360670 BOLT ..................................................................1................Z482E2B AND Z482-E3B
100 0102350675 BOLT 1
130 1587704140 SEAL, OIL 1
150 1685136950 SPRING 1
160 1584136930 SEAT, VALVE 1
170 0771503211 BALL 1
180 1584633110 FLANGE, OIL FILLER 1
190 1381133140 PLUG, OIL FILLER 1
200 0481106230 O-RING 1
210 1946188132 GASKET, H/M GEAR CASE 1
220 1522188210 STUD 3
230 0205650060 NUT 3
240 0451260060 WASHER, LOCK 3
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 97
KUBOTA Z482-EB/E2B/E3B ENGINE — HEAD COVER ASSY.
PAGE 98 — DA7000 SERIES GENERATORS• OPERATION AND PARTS MANUAL — REV. #5 (01/20/11)
KUBOTA Z482-EB/E2B/E3B ENGINE — HEAD COVER ASSY.
HEAD COVER ASSY. (Z482-EB)
NO. PART NO. PART NAME QTY. REMARKS
010 1588105550 JOINT, BREATHER PIPE 1
020 1584105140 PLATE, BREATHER ELEMENT 1
030 1584105150 PLATE, BREATHER ELEMENT 1
040 1584105670 ELEMENT, BREATHER 1
050 1584105370 OIL SHIELD, BREATHER 1
060 1686193310 SCREW 2
070 1584705512 PIPE, BREATHER 1
080 1584105590 CLAMP, PIPE 1
090 0211450080 NUT 1
100 0401360080 WASHER, FLATT 2
110 1685114512 COVER, CYLINDER HEAD ...............................1................Z482-EB
120 1685114522 GASKET, HEAD COVER 1
130 1584114620 NUT, CAP 2
140 1560196650 GASKET 2
150 1585233140 PLUG, OIL FILLER 1
160 0481150300 O-RING 1
DA7000 SERIES GENERATORS • OPERATION AND PARTS MANUAL — REV. #5 (01/20/11) — PAGE 99
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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