DA7000SSA2-SSA2GH-rev 1-op-manual

OPERATION MANUAL

2

MODEL

DA7000SSA2

DA7000SSA2GH

PORTABLE GENERATORS

(KUBOTA Z482-E4B-DGDE-2 DIESEL ENGINE)

Revision #1 (02/10/17)

To find 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 — DA7000SSA2/SSA2GH GENERATOR• OPERATION MANUAL — REV. #1 (02/10/17)

DA7000SSA2/SSA2GH

Generator

Proposition 65 Warning ........................................... 2

Safety Information ................................................ 4-8

Specifications (Generator) ....................................... 9

Specifications (Engine) .......................................... 10

Dimensions ............................................................ 11

Installation ........................................................ 12-13

General Information ............................................... 14

Components (Generator) .................................. 15-18

Components (Engine) ............................................ 19

Load Applications .................................................. 20

Inspection/Setup ............................................... 21-25

Operation .......................................................... 26-27

Operation/Shutdown .............................................. 28

Preparation For Long Term Storage ...................... 29

Maintenance ..................................................... 30-34

Generator Wiring Diagram .................................... 35

Engine Wiring Diagram ......................................... 36

Troubleshooting (Engine And Generator) .............. 37

Troubleshooting (Engine) .................................. 38-39

NOTICE

Specifications and part numbers are subject to change without notice.

TABLE OF CONTENTS

DA7000SSA2/SSA2GH GENERATOR• OPERATION MANUAL — REV. #1 (02/10/17) — PAGE 3

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.

SAFETY INFORMATION

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.

WARNING


COULD result in DEATH or SERIOUS INJURY.

CAUTION


COULD result in MINOR or MODERATE INJURY.

NOTICE

Addresses practices not related to personal injury.


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 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.



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



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



ALWAYS check the equipment for loosened threads or bolts before starting.



DO NOT use the equipment for any purpose other than its intended purposes or applications.

NOTICE

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



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



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

GENERATOR SAFETY

DANGER



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

bodily harm or even death.

WARNING



NEVER disconnect any emergency or safety devices.

These devices are intended for operator safety.

Disconnection of these devices can cause severe injury, bodily harm or even death. Disconnection of any of these devices will void all warranties.

CAUTION



NEVER lubricate components or attempt service on a running machine.

NOTICE



ALWAYS ensure generator is on level ground before use.



ALWAYS keep the machine in proper running condition.



Fix damage to machine and replace any broken parts immediately.



ALWAYS store equipment properly when it is not being used. Equipment should be stored in a clean, dry location out of the reach of children and unauthorized personnel.


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.


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.

ELECTRICAL SAFETY

DANGER



DO NOT touch output terminals during operation. Contact with output terminals during operation can cause

electrocution, electrical shock or burn.



The electrical voltage required to operate the generator can cause severe injury or even death through physical contact with live circuits. Turn generator and all circuit breakers

OFF before performing maintenance on the generator or making contact with output terminals.



NEVER insert any objects into the output receptacles during operation. This is extremely dangerous. The possibility exists of

electrical shock, electrocution or

death.


 Backfeed to a utility system can cause

electrocution and/or property damage.

NEVER connect the generator to a building’s electrical system without a transfer switch or other approved device. All installations should be performed by a

licensed electrician in accordance with all applicable laws and electrical codes. Failure to do so could result in electrical shock or burn, causing

serious injury or even death.

Power Cord/Cable Safety

DANGER



NEVER let power cords or cables lay in water.



NEVER stand in water while AC power from the generator is being transferred to a load.



NEVER use damaged or worn cables or cords when connecting equipment to generator. Inspect for cuts in the insulation.



NEVER grab or touch a live power cord or cable with wet hands. The possibility exists of

electrical shock, electrocution or death.



Make sure power cables are securely connected to the generator’s output receptacles.

Incorrect connections may cause electrical shock and damage to the generator.

NOTICE



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

Chart in this manual.

Grounding Safety

DANGER



ALWAYS make sure that electrical circuits are properly grounded to a suitable earth ground (ground rod) per the National Electrical Code (NEC) and local codes before operating generator.

Severe injury or death by

electrocution can result from operating an ungrounded generator.



NEVER use gas piping as an electrical ground.


BATTERY SAFETY

DANGER



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



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

WARNING



ALWAYS wear safety glasses when handling the battery to avoid eye irritation.

The battery contains acids that can cause injury to the eyes and skin.

 Use well-insulated gloves when picking up the battery.



ALWAYS keep the battery charged. If the battery is not charged, combustible gas will build up.



ALWAYS recharge the battery in a well-ventilated environment to avoid the risk of a dangerous concentration of combustible gasses.

 If the battery liquid (dilute sulfuric acid) comes into contact with

clothing or skin, rinse skin or clothing immediately with plenty of water.



If the battery liquid (dilute sulfuric acid) comes into contact with eyes, rinse eyes immediately with plenty of water and contact the nearest doctor or hospital to seek medical attention.

CAUTION



ALWAYS disconnect the NEGATIVE battery terminal before performing service on the generator.



ALWAYS keep battery cables in good working condition.

Repair or replace all worn cables.

ENVIRONMENTAL SAFETY/DECOMMISSIONING

NOTICE

Decommissioning is a controlled process used to safely retire a piece of equipment that is no longer serviceable.

If the equipment poses an unacceptable and unrepairable safety risk due to wear or damage or is no longer cost effective to maintain (beyond life-cycle reliability) and is to


be decommissioned (demolition and dismantlement),be sure to follow rules below.



DO NOT pour waste or oil directly onto the ground, down a drain or into any water source.

 Contact your country's Department of

Public Works or recycling agency in your area and arrange for proper disposal of any electrical components, waste or oil associated with this equipment.



When the life cycle of this equipment is over, remove battery and bring to appropriate facility for lead reclamation. Use safety precautions when handling batteries that contain sulfuric acid.

 When the life cycle of this equipment is over, it is recommended that the trowel frame and all other metal parts be sent to a recycling center.

Metal recycling involves the collection of metal from discarded products and its transformation into raw materials to use in manufacturing a new product.

Recyclers and manufacturers alike promote the process of recycling metal. Using a metal recycling center promotes energy cost savings.

EMISSIONS INFORMATION

NOTICE

The diesel engine used in this equipment has been designed to reduce harmful levels of carbon monoxide

(CO), hydrocarbons (HC) and nitrogen oxides (NOx) contained in diesel exhaust emissions.

This engine has been certifi ed to meet US EPA Evaporative emissions requirements in the installed confi guration.

Attempting to modify or make adjustments to the engine emission system by unauthorized personnel without proper training could damage the equipment or create an unsafe condition.

Additionally, modifying the fuel system may adversely affect evaporative emissions, resulting in fi nes or other penalties.

Emission Control Label

The emission control label is an integral part of the emission system and is strictly controlled by regulations.

The label must remain with the engine for its entire life.

If a replacement emission label is needed, please contact your authorized engine distributor.


SPECIFICATIONS (GENERATOR)

AC Generator

60 Hz AC Power Source

Battery

Dimensions

(L x W x H)

Dry Net Weight

Table 1. Specifications (Generator)

Model

Type

Excitation

Speed

Cooling System

Max Power Output

Continuous Power Output

Rated Voltage

Current Max/Continuous (120V)

Current Max/Continuous (240V)

Phase

Frequency

Power Factor

DA7000SSA2/SSA2GH

2-Pole Brushless Revolving Field Type

Solid State, Statically Excited System

3,600 RPM

Self-Ventilation

7 kW

6 kW

120/240V

58.3/50 amps

29.2/25 amps

Single Phase (3 wire)

60 Hz

1

12 -35Ah x 1

25.6 x 44.9 X 31.3 in.

(650 X 1,140 X 795 mm)

527 lbs. (239 kg)

NOTICE

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


Engine

SPECIFICATIONS (ENGINE)

Table 2. Specifications (Engine)

Kubota Engine Model

Tier

Gen. Enclosure Color

Type

Bore X Stroke

Displacement

Number of Cylinders

Max Output

Fuel

Fuel Capacity

Fuel Consumption

Coolant Capacity

Lube Oil Capacity

Oil Alert System

Starting Method

Battery

Z482-E4B-DGDE-2

4

White

Vertical, water-cooled, 4-cycle diesel engine

2.64 in. X 2.68 in.

(67 mm x 68 mm.)

29.23 cu.-in. (479 cm

3

)

2

12.5~13.9 H.P./3600 R.P.M.

#2 Diesel Fuel

6.6 gal. (25 liters)

0.7 gals. (2.63 liters)/hr.

2.95 quarts (2.8 liters)

2.64 quarts (2.5 liters)

Yes

Electric Start

12 Volt @ 35 Ah

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).


DIMENSIONS

A

D

E

B C

I

F

G

H

J

K

Figure 1. Dimensions

L

Housing

Approx. Dry Weight

Approx. Wet Weight

Table 3. Dimensions

A

approx. 34.3 in

(870 mm)

E

44.9 in

(1140 mm)

I

approx. 40.4 in

(1025 mm)

B

29.1 in

(740 mm)

F

31.3 in

(795 mm)

J

C

7.9 in

(200 mm)

G

28.3 in

(720 mm)

K

23.2 in

(590 mm)

25.6 in

(650 mm)

527 lbs (239 kg)

582 lbs (264 kg)

D

approx. 6.5 in

(165 mm)

H

12.8 in

(325 mm)

L

approx. 17.9 in

(455 mm)


INSTALLATION

CONNECTING THE GROUND

Consult with local Electrical and Safety Codes for proper connection based on condition of use.

EXAMPLE of how to ground the unit if the condition of use requires such a device:

The nut and ground terminal on the generator should always be used to connect the generator to a suitable ground when required. 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).

GENERATOR

GROUND LUG

GROUND CABLE

GROUND ROD FOR

EARTH GROUND.

CONNECT TO BUILDING

GROUND IF APPLICABLE

8 FT

./2.4 M (MINIMUM)

REFERENCE

NEC 250-83 (C)

Figure 2. Generator Grounding


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

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 flat 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.

INSTALLATION

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

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 mm

2

) b. Aluminum - 6 AWG (8.4 mm

2

)

2. When grounding the generator (Figure 2) connect the ground cable between the lock washer and the nut on the generator and tighten the nut fully. Connect the other end of the ground cable to earth ground.

3. NEC article 250-52(c) specifies 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.


Generator

The Multiquip DA7000SSA2/SSA2GH is a 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), 120/240V for lighting facilities, power tools, submersible pumps and other industrial and construction machinery.

Control Panel

The control box is provided with the following:

120 VAC Receptacle (5-20R)

120 Twist-Lock Output Receptacle (L5-30R)

120/240 V Twist-Lock Output Receptacle (L14-30R)

120/240 V Twist-Lock Output Receptacle (CS6369)

AC Voltmeter

GFCI Sensing Module

Main Circuit Breaker @25 Amps

30 Amp Circuit Breaker (for L14-30R)

30 Amp Circuit Breaker (for L5-30R)

20 Amp Circuit Breaker (for 5-20R)

Idle Control Switch

Full Power Switch

Starter Switch

Warning Lamp Unit

Hour Meter

Ground Terminal

Engine Protection System

Engine protection fail safe features are provided in the event of low oil pressure, high coolant temperature and failure of the battery to charge. If any of the above conditions occur while operating the generator it will cause a complete unit shut down.

Battery Charge Alarm

This unit is equipped with a protective shutdown device that signals the emergency relay and automatically stops the engine when loss of charge from the engine alternator occurs. An indicator lamp will be displayed on the control panel.

Water Temperature Alarm

This unit is equipped with a temperature switch that signals the emergency relay and automatically stops the engine when the temperature of the engine coolant becomes abnormally high. The coolant temperature switch will not

GENERAL INFORMATION

function properly if the machine is operated with less than the proper amount of coolant.

Oil Pressure Warning Alarm

This unit is equipped with an oil pressure switch that detects low oil pressure. If the lubricating oil pressure of this unit should become abnormally low, the oil pressure switch signals the emergency relay to shutdown the engine. If this condition should occur, please refer to the engine troubleshooting table in this manual.

Idle Control Switch

The DA7000SSA2/SSA2GH generator is 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 when the switch is in the ON position.

With AC loads of more than 100W (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 drawing more than 150W are connected. Turn the idle control switch to the “OFF” (down) position when

AC loads drawing less than 100W or when a magnetic switch is used.

Excitation System

The DA7000SSA2/SSA2GH 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 winding in the stator. Current applied to this coil creates a magnetic field. The rotating armature within the stator is then induced with AC current.

Engine

The DA7000SSA2/SSA2GH generators are powered by a water-cooled, 4-cycle KUBOTA diesel engine. This engine is designed to meet every performance requirement of the generator. Reference Table 2, engine specifications.

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


COMPONENTS (GENERATOR)

Figure 3. Generator Components (1 of 3)

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

10. Automatic Idle Control Solenoid — Automatically regulates engine speed depending on load.

2.

4.

Air Outlet Exhaust — Allows engine exhaust to exit the generator into the open air. opening.

fuel immediately.

527 lb. (239 kg).

NEVER block this

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

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 filter cannister to gain access to filter element.

6.

Expansion Bottle — Supplies coolant to the radiator when radiator coolant level is low. Fill to indicated level as shown on expansion bottle.

11. Battery Terminals — Connect these output cables to the terminals on 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.

Oil Filter — Provides filtering for the engine oil. Change oil filter as recommended in the maintenance section of this manual.

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

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

Table 6.

8.

Coolant Drain Plug — Remove this plug to drain coolant from the radiator.

9. Oil Drain Plug — Remove this plug to drain oil from the engine.

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.


26

27


22

21

20

19

25

24

23

18

17

17.

19.

20.

21.


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 based on condition of use.

120/240V Output Receptacle — CS6369 twist-lock receptacle provides 240 V, 60 Hz output at 25 amps, or 120V, 60 Hz at 50 amps (X2), depending on the position of the full power switch.

120/240V Output Receptacle — NEMA L14-30R twist-lock receptacle provides 240 V, 60 Hz output at

25 amps, or 120V, 60 Hz at 30 amps (X2), depending on the position of the full power switch.

120V Output Receptacles — NEMA 5-20R twist-lock receptacle provides 120V, 60 Hz output at 30 amps, depending on the position of the full power switch.

22.

Duplex Receptacle — NEMA 5-20R receptacle provides 120V, 60 Hz output at 20 amps.

23. 30 Amp Breaker (for L14-30R) — Single-pole, 30 Amp circuit breaker protects the 120V twist-lock receptacle.

When starting the generator, always have this circuit breaker placed in the "OFF" position.

24.

30 Amp Breaker (for L5-30R) — Single-pole, 30 Amp circuit breaker protects the 120V twist-lock receptacle.


25.

20 Amp Breaker (for 5-20R) — Single-pole, 20 Amp circuit breaker protects the 120V duplex receptacle.


26. GFCI Sensing Module — Interrupts power, by opening the main breaker, when a ground fault exists.

27. Main Breaker — 2-pole, 25 Amp circuit breaker protects the generator from short circuiting or overloading. When starting the generator, always have this circuit breaker placed in the "OFF" position.



28

30

31

32

29

33


28.

AC Voltmeter — This voltmeter indicates (with a mark) the rated 60 Hz (single-phase) output voltage.

In addition the voltmeter can also be used as a diagnostic tool. If the voltmeter indicator (needle) is below the rated voltage, engine problems may exist

(low/high RPM's). To prevent damage to the generator or power tools turn the generator OFF and consult your authorized Multiquip service dealer.

29.

Hour Meter — Indicates number of hours machine has been in use or hours engine was run.

30.

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

31.

32. to about 3600 rpm (high-speed operation) as soon as the load is connected.

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 loss of engine alternator charge exists 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.

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

33. Ground Terminal — Used to connect exernal equipment ground so that the GFCI receptacle will have a ground path.



34

120V

AC CIRCUIT BREAKER

G.F.C.I. PROTECTED

WHISPERWATT

7kW AC GENERATOR

240V/120V

FULL POWER

SWITCH

AC VOLTMETER

ALL RECEPTECALES

G.F.C.I. PROTECTED

A9210 0260

ON

STOP

RUN

HEAT

OFF

IDLE CONTROL

QUARTZ

STARTER SWITCH

START

HOUR METER

CIRCUIT BREAKER

S-3031 for 120V

20A for 120V

30A for 120V/240V

30A

20A

120V

30A 30A

AC POWER OUTPUT

120V/240V

50A

A55200000A

GROUND for

G.F.C.I

S-3821

Figure 6. Full Power Switch

34.

Full Power Switch — The generator is provided with a full power switch. See for simplified wiring diagrams of the dual voltage system.

When the full power switch is in the 120 Volt position

(up), you can access the full rated power of the generator at 120 Volts from the duplex receptacle and the 120V twist-lock receptacle, or a combination of both receptacles as long as the total load does not exceed the generating set capacity.

When the full power switch is in the 240 Volt position

(down), you can access half of the rated power of the generator at 120 Volts from the duplex receptacle and up to half of the rated power of the generator at 120

Volts from the 120V twist-lock receptacle, or full rated power of the generator at 240 Volts from the 240V twist-lock receptacle.

CB

U2

V2

U1

V1

W

V

SW 120V

9 8 7

6

3

5

2

4

1

CB

B V

22

Y

CB1

CB1

CB3

X

CON3

W

G CON4

V

CON1

Y

G

Y

W

Y

CON2

G

V

Figure 7. 120V Full Power Switch

Simplified Diagram (Up Position)

U1

V1

U2

V2

W

V

SW 120V/240V

9 8 7

6 5 4

3 2 1

B V

22

Y

CB1

CB1

W

X

CON3

G

CON4

CB3

V

CON1

Y

G

Y

W

Y

CON2

G

V

Figure 8. 240/120V Full Power Switch

Simplified Diagram (Down Position)

NOTICE

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


COMPONENTS (ENGINE)

Figure 9. Kubota Z482 Series

INITIAL SERVICING

The engine (Figure 9) must be checked for proper lubrication and filled with fuel prior to operation. Refer to the manufacturer's engine manual for instructions and details of operation and servicing.

1.

Water Drain Cock — Open this cock to drain water

2.

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

3. Fuel Feed Pump — Pumps fuel to the injection system.

4. Oil Dip Stick/Gauge — Remove to check amount and condition of oil in crankcase. Refill or replace with recommended type oil as listed in Table 6.

5.

Speed Control Lever — Controls engine speed. This lever is factory set at 3600 rpm to maintain proper voltage and frequency. DO NOT adjust this lever out of factory range.

6.

Injector Pump — Provides fuel under pressure to the injector nozzles.

7. Air Filter — Prevents dirt and other debris from entering the air intake system. Loosen clips on side of air filter canister to gain access to filter element.

Replace with manufacturer's recommended type air cleaner only.

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 6. Crankcase holds a maximum of 2.64 quarts

(2.5 liters) of motor oil.

11.

Starter — Starts engine when ignition key is rotated clockwise to the "

ON" position.

12.

Oil Filter — Spin-on type, filters oil contaminants.

Replace filter 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 6.


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 influenced by the efficiency, 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 4 below when connecting loads.

Table 4. Power Factor By Load

Type Of Load Power Factor

0.4 - 0.75

Single-phase induction motors

Electric heaters, incandescent lamps

Fluorescent lamps, mercury lamps

Electronic devices, communication equipment

Common power tools

1.0

0.4 - 0.9

1.0

0.8

NOTICE

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

NOTICE

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

LOAD APPLICATIONS

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

1. INCANDESCENT LOADS

Lights, heaters and similar appliances. total the running wattage and multiply by 1.

Example:

29 light bulbs @ 100W each = 2.9 kW use a 3 kW generator.

2. SMALL MOTORS

Drills and other small power tools.

Total the running wattage and multiply by 2.

Example:

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

3. LARGE MOTORS

Submersible pumps, table saws etc.

Total the running wattage and multiply by 3.

Example:

A conveyor belt runs at 8 kW use a 24 kW generator.

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 5) 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.


INSPECTION/SETUP

GENERAL INSPECTION PRIOR TO OPERATION

Ground Power Tools

When using power tools or electrical equipment requireing

AC power from the generator, make sure power tool cord has a ground pin or is double insulated as shown in Figure 10.

GROUND

PIN REMOVED

GROUND

PIN

TWIST-LOCK

RECEPTACLES

GROUND

PIN

DUPLEX

RECEPTACLE

3-PRONGED

AC PLUG

DOUBLE

INSULATED

Figure 10. Ground Pin

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 5) 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 aux circuit breakers in the

OFF position prior to starting the engine.

Current In

Amperes

2.5

5

7.5

10

15

20

Table 5. Cable Selection (60 Hz, Single Phase Operation)

Load In Watts

120 Volts 240 Volts

300

600

900

1200

600

1200

1800

2400

#10 Wire

1000 ft.

500 ft.

350 ft.

250 ft.

Maximum Allowable Cable Length

#12 Wire

600 ft.

300 ft.

200 ft.

150 ft.

#14 Wire

375 ft.

200 ft.

125 ft.

100 ft.

1800

2400

3600

4800

150 ft.

125 ft.

CAUTION: Equipment damage can result from low voltage.

100 ft.

75 ft.

65 ft.

50 ft.

#16 Wire

250 ft.

125 ft.

100 ft.


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. Caution must be taken to ensure generator is 100% dry before use.

3. Check the air filter for dirt and dust. If air filter is dirty, replace air filter with a new one as required.

4. Check fastening nuts and bolts for tightness

Engine Oil Check

1. To check the engine oil level, place the generator on secure level ground with the engine stopped.

2. Remove the dipstick from its holder (Figure 11) and wipe clean.


4. If the oil level is low, remove the oil filler cap (Figure 13) and fill to a safe operating level (max) as indicated by the dipstick. Fill with recommended type oil as listed in

Table 6. Maximum oil capacity is 2.64 quarts (2.5 liters).

Figure 11. Engine Oil Dipstick Removal

3. Re-Insert dipstick (Figure 12), then remove dipstick from its holder. Check the oil level shown on the dipstick.

Figure 13. Engine Oil Filler Port

Temperature

Table 6. Oil Type

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

NOTICE

When adding engine oil

DO NOT overfill.

Figure 12. Engine Oil Dipstick


Fuel Check

Fill the fuel tank with #2 diesel fuel.

DO NOT fill 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 filling. 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 14) to determin if the fuel level is low.

Figure 14. Fuel Gauge

2. If fuel is low, remove the fuel cap (Figure 15) located on top of the generator and replenish with clean #2 diesel fuel.

Figure 15. Adding Fuel

DANGER

Motor fuels are highly flammable and can be dangerous if mishandled.

DO NOT smoke while refueling.

DO NOT attempt to refuel the generator if the engine is hot!, running or in the dark.

NOTICE

When refueling, be sure to use a strainer for filtration.

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


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 7 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.

Table 7. 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 8) has been added.

Table 8. Anti-Freeze Operating

Temperatures

Vol %

Anti-Freeze

Freezing Point

°C °F

50 -37 -34

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 fins become overloaded with dust or debris. Periodically clean the radiator fins with compressed air. Cleaning inside the machine is dangerous, so clean only with the engine turned off and the

negative battery terminal disconnected.

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 insufficient charging of the battery. Inspect the fan belt for damage and wear and adjust it in accordance with the

Kubota Engine Owner's Manual.

The fan belt tension is proper if the fan belt bends 10 to 15 mm (Figure 16) when depressed with the thumb as shown below.


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 sufficiently charged if the specific gravity of the battery fluid is 1.28 (at 68° F). If the specific gravity should fall to 1.245 or lower, it indicates that the battery is dead and needs to be recharged or replaced.

Before charging the battery with an external electric source, be sure to disconnect the battery cables.

Battery Cable Installation

ALWAYS be sure the battery cables (Figure 17) 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.

NEGATIVE

POSITIVE

Figure 16. Fan Belt Tension

CAUTION

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

BATTERY

This unit is of negative ground

DO NOT connect in reverse.

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

Figure 17. Battery Connections

When connecting battery do the following:

1. NEVER connect the battery cables to the battery terminals when the

Ignition Switch is in the START position.

ALWAYS make sure that the Ignition Switch is in the OFF position when connecting the battery.


2. Place a small amount of battery terminal treatment compound around both battery terminals. This will ensure a good connection and will help prevent corrosion around the battery terminals.

NOTICE

If the battery cable is connected incorrectly, electrical damage to the generator will occur. Pay close attention to the polarity of the battery when connecting the battery.

CAUTION

Inadequate battery connections may cause poor starting of the generator, and create other malfunctions.

ALTERNATOR

The polarity of the alternator is negative grounding type.

When an inverted circuit connection takes place, the circuit will be in short circuit instantaneously resulting the alternator failure.

DO NOT put water directly on the alternator. Entry of water into the alternator can cause corrosion and damage the alternator.

WIRING

Inspect the entire generator for bad or worn electrical wiring or connections. If any wiring or connections are exposed

(insulation missing) replace wiring immediately.

PIPING AND HOSE CONNECTION

Inspect all piping, oil hose, and fuel hose connections for wear and tightness. Tighten all hose clamps and check hoses for leaks.

If any hose (

fuel or oil) lines are defective replace them immediately.



Before Starting the Engine

CAUTION

The engine’s exhaust contains harmful emissions.

ALWAYS have adequate ventilation when operating.

Direct exhaust away from nearby personnel.

NOTICE

The DA7000SSA2/SSA2GH generator is equipped with a GFCI sensing module. The purpose of this module is to sense a ground fault during operation of the generator and open the main breaker once the ground fault has been detected.

Multiquip recommends that the GFCI sensing module be tested before each use of the generator. Refer to the maintenance section of this manual for testing of the

GFCI module.

1. Open the cabinet door and turn the fuel cock lever

(Figure 18) to the “ON” position.

OPERATION

3.

NEVER start the engine with the main circuit breaker in the

ON position. Always place circuit breaker (Figure 20) in the OFF position before starting.

Figure 20. Main Circuit Breaker (OFF)

4.

NEVER start the engine with the auxiliary circuit breakers in the ON position. Always place circuit breakers (Figure 21) in the OFF position before starting the engine.

Figure 21. Auxiliary Circuit Breakers (OFF)

Starting the Engine

1. Insert the key into the starter switch (Figure 22) 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. Fuel Cock Lever (ON)

2.

NEVER operate the generator with the doors open

(Figure 19). Operation with the doors open may cause insufficient cooling of the unit, and engine damage may result. Close the doors for normal operation.

Figure 22. 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. In cold weather conditions, it may be required to extend the duration of the HEAT position for proper starting.

Figure 19. Generator Doors


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 steps 1-3.

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 five minutes with the

Idle Control

Switch (Figure 23) placed in the ON position.

Figure 25. Auxiliary Circuit Breakers (ON)

3. Read the voltmeter on front panel of generator (Figure

26) and verify that 120 VAC is displayed. Using an external voltmeter as shown in Figure 26, verify that

120 VAC is present at the 120V twist-lock and duplex receptacles.

X

120VAC

W

L5-30R

NEMA 5-20R

Figure 23. Idle Control Switch (ON)

NOTICE

Placing the idle control switch (Figure 23) in the

OFF position allows the engine to operate at a maximum speed of about 3600 RPM's.

When the idle control switch is placed in the up position

( ON), the generator will run at idle speed (2200 RPM's) until a load is applied, at that time the engine speed will increase to 3600 RPM's as long as a load is being applied.

When the load is not in use, the engine speed will drop back to the idle mode after about 3 seconds.

Output Voltage Verification

1. Place

main circuit breaker (Figure 24) in the ON position.

ON

I

O

OFF

Figure 24. Main Circuit Breaker (ON)

OPERATION

2. Place auxiliary

circuit breakers (Figure 25) in the ON position.

V

120

240

120 VAC

OF F

V~

V

300 mV

A

A~

V

COM

Figure 26. 120V GFCI/L5-30R Receptacles

NOTICE

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


4. The CS-6369 receptacle is a dual voltage receptacle

(120/240 volts). Using an external voltmeter as shown in Figure 27, verify that 120/240 VAC is present at the

CS-6369 twist-lock receptacle.

Y

Y

120VAC

X

X

W

CS-6369

CS-6369

W

OPERATION/SHUTDOWN

Stopping the Engine (Normal Shutdown)

1. Place

main circuit breaker (Figure 29) in the OFF position.

ON

I

O

OFF

Figure 29. Main Circuit Breaker (OFF)

2. Place auxiliary circuit breakers (Figure 30) in the OFF position.

V

120

240

240 VAC

OF F

V~

V

300 mV

A

A~

Y

L14-30R

V

COM

Figure 27. 120/240 CS-6369 Receptacle

5. The L14-30R receptacle is a dual voltage receptacle

(120/240 volts). Using an external voltmeter as shown in Figure 28, verify that 120/240 VAC is present at the

L14-30R twist-lock receptacle.

X

X

G W

120VAC

G W

Y

L14-30R

Figure 30. Auxiliary Circuit Breakers (OFF)

3. Place idle control switch switch (Figure 31) in the

ON

position.

Figure 31. Idle Control switch (ON)

4. Let engine run at idle with no load for 3-5 minutes.

5. Place the starter switch key (Figure 32) in the STOP position and remove the key. Place fuel cock lever in the

OFF position.

120

240

240 VAC

OF F

V~

V

300 mV

V

A~

A

Figure 32. Starter Switch (Stop Position)

V

6. Remove all load connections from the generator.

COM

Emergency Shutdown

Figure 28. 120/240V L14-30R Receptacle

6. Connecting of loads (power tools, lighting ect.) to the generator receptacles can now be done.

1. Place starter switch key in STOP position. Remove key.

Place fuel cock lever in the

OFF position.


PREPARATION FOR LONG TERM STORAGE

Generator Storage

For storage of the generating set for over 30 days, the following is required:

Run the engine until all the fuel is completely consumed.

Drain the fuel tank completely, or add STA-BIL to the fuel

Completely drain the oil from the crankcase and refill with fresh oil.

Disconnect the

negative battery cable from the battery.

Clean all external parts of the generating set with a cloth.

If generator is mounted on a trailer, jack trailer up and place on blocks so tires do not touch the ground or block and completely remove the tires.

Cover the generating set and store in a clean, dry place.


MAINTENANCE

Use Table 9 as 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 9. Engine Maintenance Schedule

DESCRIPTION

(3)

OPERATION DAILY

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

OR

800 HRS.

Engine Oil

CHECK

CHANGE

Oil Filter

Cartridge

CHANGE

Air Cleaner

Element

All Nuts & Bolts

Cooling Fins

Fuel Tank

Fuel Filter

CHECK

CHANGE

RETIGHTEN IF

NECESSARY

CHECK

CLEAN

CLEAN

Fuel Filter

Element

Fuel lines

CHANGE

CHANGE

Battery

Radiator Hoses/

Clamps

CHANGE

CHANGE

Radiator

Coolant

CHANGE

Idle Speed CHECK-ADJUST

Valve Clearance CHECK-ADJUST

X

X

X

X

X

X

X

X (1)

X

Every 2 years, replace if necessary (2)

Every 2 years, replace if necessary (2)

X

X

X (2)

X

X

X

X

X

X

X

X

X (2)

Fan Belt

CHECK

TIGHTNESS

WATER

SEPARATOR

DRAIN

(1) Service more frequently when used in

DUSTY

areas.

X

X

(2) These items should be serviced by your service dealer, unless you have the proper tools and are mechanically proficient. Refer to the KUBOTA

Shop Manual for service procedures.

(3) For commercial use, log hours of operation to determine proper maintenance intervals.

NOTICE

Thoroughly remove dirt and oil from the engine and control area. Clean or replace the air cleaner elements as necessary. Check and retighten all fasteners as necessary.


Maintenance

Perform the scheduled maintenance procedures as defined by Table 9 and below:

Engine Oil

Every 200 hours: Change engine oil after the first 50 hours of operation and 200 hours thereafter. Always check the crankcase oil level prior to each use, or when the fuel tank is filled. Insufficient oil may cause severe engine damage.

Make sure generator is level when checking oil level. The oil level must be between the two notches on the dipstick as shown in Figure 12.

1. Remove engine oil drain plug located at the bottom of the generator enclosure (Figure 33) and drain oil from crankcase.For best results drain oil while engine is warm. Reinstall oil drain plug, and add engine oil as specified in Table 6. Crankcase oil capacity is 2.64 qts.

(2.5 liters).

MAINTENANCE

2. Screw on new oil filter by hand until seal contacts the filter mounting base. Install drain bolt with sealing washer and hand tighten.

NOTICE

When installing the oil filter, coat rubber seal with a small amount of lubricant (motor oil).

DO NOT overtighten cartridge. Hand tighten only.

3. Replace engine oil with recommended type oil as listed in Table 6. For engine oil capacity, see Table 2 (engine specifications). Fill to upper limit as shown in Figure 12.

Engine Air Filter

Every 50 hours: Replace air filter employed on the

KUBOTA Z482 series engines. This is a dry type filter.

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 35) and remove the air cleaner element.

ELEMENT

AIR FILTER BODY

Figure 33. Engine Oil Drain Plug

Oil Filter Cartridge

Every 200 hours: Replace the engine oil filter cartridge after every 200 hours of operation.

1. Clean oil filter mounting base, and coat oil filter seal

(Figure 34) with clean engine oil.

RETAINING

CLAMP

Figure 35. Air Cleaner

2. Wipe the inside of the air cleaner with a clamp cloth and remove all dust and debris that may have accumulated inside air cleaner body.

3. Remove and replace filter element with a factory replacement only; do not oil.

Figure 34. Oil Filter Cartridge


Cleaning the Fuel Filter

Every 100 hours: Clean fuel filter every 100 hours of operation or once a month to remove dust or water.

1. Place fuel cock lever (Figure 36) in the close position.

2. Disconnect fuel lines from fuel filter.

MAINTENANCE

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 38).

Make sure the level is between the FULL (

H) and LOW

( L) markings. Fill reserve tank with a mixture of 50/50 antifreeze/water.

Figure 36. Fuel Cock Lever (OFF)

Replacing Fuel Filter Element

First 50 And Then Every 200 hours: Replace fuel filter element.

1. Remove the top cap (Figure 37) from the fuel filter and rinse cap and filter bowl with diesel fuel.

2. Remove element, and rise with diesel fuel.

3. Reinstall fuel filter and connect fuel lines.

Figure 38. Radiator/Reserve Tank

Flushing Out Radiator and Replacing Coolant

1. Remove radiator coolant plug (Figure 39) located at the bottom of the generator enclosure and drain radiator coolant. Open the radiator cap while draining.

Remove the overflow tank and drain.

COOLANT DRAIN

PLUG

COOLANT DRAIN

OIL DRAIN

Figure 37. Fuel Filter Disassembly

4. Inspect all fuel lines every 50 hours.

Figure 39. Coolant Drain Plug


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; replace as needed.

4. Tighten coolant drain plug and reinstall the overflow tank.

5. Fill with coolant as recommended by the engine manufacturer.

6. Close radiator cap tightly.

WARNING

Allow engine to

cool when flushing out radiator. Flushing the radiator while hot could cause serious burns from water or steam.

RADIATOR CLEANING

The radiator (Figure 40) should be sprayed (cleaned) with a high pressure washer when excessive amounts of dirt and debris have accumulated on the cooling fins or tube.

When using a high pressure washer, stand at least 5 feet

(1.5 meters) away from the radiator to prevent damage to the fins and tube.

MAINTENANCE

TESTING THE GFCI MODULE

If tripping of the main circuit breaker persists after a load is replaced with a known good one (no short circuit), perform this test with no load.

1. Start the generator as outlined in the startup procedure in this manual.

2. Place the main circuit breaker in the ON position

(Figure 41).

Figure 41. Main Circuit Breaker ON (GFCI Test)

3. On the GFCI module, verify that the green power LED is ON (Figure 42).

Figure 42. GFCI Module (Green LED ON)

4. Also verify that the AC voltmeter is registering a voltage reading as shown in Figure 46.

Figure 40. Radiator Cleaning


5. Next, press the TEST button on the GFCI module and verify that the green POWER LED turns OFF and the red fault LED turns

ON (Figure 43).

MAINTENANCE

8. Verify that the AC voltmeter is registering a voltage reading as shown in Figure 46.

Figure 43. GFCI Module (Red/Fault LED ON)

6. Also verify that the main circuit breaker switch trips to the

OFF position (Figure 44).

Figure 46. AC Voltmeter (120/240V)

NOTICE

It is recommended that the GFCI module be tested when the generator is initially taken out of the box.

Then, the generator should be tested daily at startup.

CAUTION

The GFCI module is designed to interrupt power when a ground fault exists to prevent injuries and shock hazards. DO NOT operate the generator if this test fails. Consult a qualified electrician for the repair or replacement of the GFCI module.

Figure 44. Circuit Breaker OFF (GFCI Test)

7. To restore power, press the

RESET button on the GFCI module and verify that the red fault LED turns

OFF and the green power LED should turn ON (Figure 45).

Figure 45. GFCI Module (Green LED ON Reset)


GENERATOR WIRING DIAGRAM

Figure 47. Generator Wiring Diagram (DA7000SSA2/SSA2GH SERIES)


ENGINE WIRING DIAGRAM

Figure 48. Engine Wiring Diagram


TROUBLESHOOTING (ENGINE AND GENERATOR)

Engine starts "Idle Control

Switch" is in OFF position and engine remains at low speed.

SYMPTOM

Engine fails to start and starter does not rotate.

Engine fails to start and starter rotates.

Table 10. Engine and Generator Troubleshooting

POSSIBLE PROBLEM

Dead Battery?

Replace Battery.

SOLUTION

Defective Starter Switch?

Defective Starter?

Fuse F5 Burned Out?

Broken Pre-Heat Circuit?

Replace Switch.

Replace Starter.

Replace Fuse.

Check Pre-Heat Circuit.

No Fuel?

Defective Wiring?

Defective Idle Control Switch?

Clogged Fuel Strainer?

Clogged Air Cleaner?

Defective Idle Control Device?

Disconnected Wiring?

Add Fuel.

Check Wiring.

Replace Switch.

Clean or Replace.

Clean or Replace.

Replace.

Check and Repair Wiring.

Engine starts and "Idle

Control Switch" is in OFF position. Engine speed rises and battery discharges too soon.

Defective Engine Regulator?

Defective Wiring?

Replace Regulator.

Repair or Replace Wiring.


Control Switch" is in OFF position. Engine speed rises and engine seems overloaded.

Defective Alternator?

Damaged Alternator Bearing?

Repair or Replace Alternator.

Replace Alternator Bearings.


Control Switch" is in OFF position. Engine speed rises and engine has abnormal noise.

Loose Engine Parts?

Defective Alternator?

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?

Defective Idle Control Switch?

Defective Solenoid?

Defective Relay?

Check All Engine Parts For Tightness.

Check Alternator for Damaged Bearing or

Loose Clamping Bolts.

Repair or Replace Idle Control Device.

Replace Idle Control Switch.

Replace Solenoid.

Replace Relay.


SYMPTOM

Engine does not start.

Starter does not run.

TROUBLESHOOTING (ENGINE)

Table 11. Engine Troubleshooting


No fuel?

Air in the fuel system?

Water in the fuel system?

Fuel pipe clogged?

Fuel filter clogged?

Excessively high viscosity of fuel or engine oil at low temperature?

Fuel with low cetane number?

Fuel leak due to loose injection pipe retaining nut?

Incorrect injection timing?

Fuel cam shaft worn?

Injection nozzle clogged?

Injection pump malfunctioning?

Seizure of crankshaft, camshaft, piston, cylinder liner or bearing?

SOLUTION

Replenish fuel.

Bleed system.

Remove water from fuel tank.

Clean fuel pipe.

Clean or change fuel filter.

Use the specified fuel or engine oil.

Use the specified fuel.

Tighten nut.

Adjust.

Replace.

Clean injection nozzle.

Repair or replace.

Repair or replace.

Compression leak from cylinder?

Improper valve timing?

Piston ring and liner worn?

Excessive valve clearance?

Battery discharged?

Starter malfunctioning?

Key switch malfunctioning?

Wiring disconnected?

Replace head gasket, tighten cylinder head bolt, glow plug and nozzle holder.

Correct or replace timing gear.

Replace.

Adjust.

Charge battery.

Repair or replace.

Repair or replace.

Connect wiring.


TROUBLESHOOTING (ENGINE)

SYMPTOM

Engine revolution is not smooth.

Either white or blue exhaust gas is observed.

Either black or dark gray exhaust gas is observed.

Deficient output.

Table 11. Engine Troubleshooting (Continued)


Fuel filter clogged or dirty?

Air cleaner clogged?

Fuel leak due to loose injection pipe retaining nut?

Clean or change.

Clean or change.

Tighten nut.

SOLUTION

Injection pump malfunctioning?

Incorrect nozzle opening pressure?

Injection nozzle stuck or clogged?

Fuel over flow pipe clogged?

Governor malfunctioning?

Excessive engine oil?

Piston ring and liner worn or stuck?


Deficient compression?

Repair or replace.

Adjust.

Repair or replace.

Clean.

Repair.

Reduce to the specified level.

Repair or replace.

Adjust.

Adjust top clearance.

Overload?

Low grade fuel used?

Fuel filter clogged?

Air cleaner clogged?

Deficient nozzle injection?

Lessen the load.

Use the specified fuel.

Clean or change.

Clean or change.

Repair or replace the nozzle.


Adjust.

Engine's moving parts seem to be seizing?

Repair or replace.

Uneven fuel injection?

Deficient nozzle injection?

Repair or replace the injection pump.

Repair or replace the nozzle.

Compression leak?

Replace head gasket, tighten cylinder head bolt, glow plug and nozzle holder.


OPERATION MANUAL

HERE’S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL

NUMBER ON-HAND WHEN CALLING

UNITED STATES

Multiquip Corporate Office

18910 Wilmington Ave.

Carson, CA 90746

Contact: [email protected]

Service Department

800-421-1244

310-537-3700

Technical Assistance

800-478-1244

Tel. (800) 421-1244

Fax (310) 537-3927

Fax: 310-943-2238

CANADA

Multiquip

4110 Industriel Boul.

Laval, Quebec, Canada H7L 6V3


Tel: (450) 625-2244

Tel: (877) 963-4411

Fax: (450) 625-8664

MQ Parts Department

800-427-1244

310-537-3700

Warranty Department

800-421-1244

310-537-3700

Fax: 800-672-7877

Fax: 310-943-2249

UNITED KINGDOM

Multiquip (UK) Limited Head Office

Unit 2, Northpoint Industrial Estate,

Globe Lane,

Dukinfield, Cheshire SK16 4UJ


Tel: 0161 339 2223

Fax: 0161 339 3226

© COPYRIGHT 2017, MULTIQUIP INC.

Multiquip Inc , the MQ logo and the MQ Power logo are registered trademarks of Multiquip Inc. and may not be used, reproduced, or altered without written permission. All other trademarks are the property of their respective owners and used with permission.

This manual MUST accompany the equipment at all times. This manual is considered a permanent part of the equipment and should remain with the unit if resold.

The information and specifi cations included in this publication were in effect at the time of approval for printing. Illustrations, descriptions, references and technical data contained in this manual are for guidance only and may not be considered as binding. Multiquip Inc. reserves the right to discontinue or change specifi cations, design or the information published in this publication at any time without notice and without incurring any obligations.

Your Local Dealer is:

Manufactured for

MQ Power Inc.

by

DENYO CO., LTD, JAPAN

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