PARTS AND OPERATION MANUAL
PARTS AND OPERATION MANUAL
MQ POWER
DCA-40SSAI
TM
WHISPERWATT
GENERATOR
PARTS LIST NO.M3340163804
FINAL COPY
MULTIQUIPINC.
PARTS DEPARTMENT:
18910 WILMINGTON AVE.
800-427-1244
CARSON, CALIFORNIA 90746 FAX: 800-672-7877
310-537-3700
800-421-1244
SERVICE DEPARTMENT:
800-835-2551
FAX:310-537-3927
FAX:310-638-8046
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PAGE 2 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
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HERE'S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL NUMBER
ON-HANDWHEN CALLING
PARTS DEPARTMENT
800/427-1244 or 310/537-3700
FAX: 800/672-7877 or 310/637-3284
SERVICE DEPARTMENT
800/835-2551 or 310/537-3700
FAX: 310/638-8046
WARRANTY DEPARTMENT
800/835-2551 or 310/537-3700
FAX: 310/638-8046
MAIN
800/421-1244 or 310/537-3700
FAX: 310/537-3927
DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 3
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TABLE OF CONTENTS
Here's How To Get Help ................................................... 3
Table Of Contents ............................................................ 4
Parts Ordering Procedures .............................................. 5
Rules for Safe Operation .............................................. 6-9
Towing andTransportation ............................................. 10
Trailer Safety Guidelines........................................... 11-17
TrailerWiring Diagram .................................................... 18
Electric Brake Troubleshooting ...................................... 19
Hydraulic Brake Troubleshooting.................................... 20
Operation and Safety Decals.................................... 21-22
DCA-40SSAI Specifications .......................................... 23
General Information ....................................................... 24
Major Components ........................................................ 25
Dimensions............................................................... 26-27
Control Panel Descriptions ....................................... 28-29
Engine Operating Panel Descriptions ....................... 30-31
OutputTerminal Panel Description ............................ 32-33
Output Amperage Setup ........................................... 34-35
Output Voltage Setup................................................ 36-39
Installation ................................................................ 40-41
Pre Setup ................................................................. 42-45
Load Application ............................................................ 46
Generator Start-up Procedure .................................. 47-49
Generator Shutdown Procedure ..................................... 50
Maintenance ............................................................. 52-55
EngineWiring Diagram ............................................. 56-57
GeneratorWiring Diagram .............................................. 58
EngineTroubleshooting ............................................. 60-62
Explanation of Codes in Remarks Column .................... 64
Suggested Spare Parts ................................................. 65
ISUZU 4BD1 ENGINE
Cylinder Head Cover Assembly ................................94-95
Cylinder Block Assembly .........................................96-99
Timing Gear Assembly ..........................................100-101
Flywheel Housing Assembly .................................102-103
Oil Pan Assembly ..................................................104-105
Oil Pump Assembly ..............................................106-107
Crankshaft Piston, Flywheel Assembly .................108-109
Valve Assembly ....................................................110-111
Oil and Fuel Filter Assembly .................................112-113
Oil Piping Assembly ..............................................114-115
Cooling Assembly .................................................116-117
Air Intake and Exhaust Assembly .........................118-119
Fuel Injection Assembly ........................................120-121
Engine Foot Assembly ..........................................122-123
Engine Control Assembly ......................................124-125
Injection Pump Assembly .....................................126-127
Electrical Parts Assembly .....................................128-129
Feed Pump Assembly ...........................................130-131
Nozzle Assembly ..................................................132-133
Oil Filter Assembly ................................................134-135
Fuel Filter Assembly ............................................. 136-137
Accessories ..........................................................138-139
Terms and Condition of Sale — Parts ....................... 140
MQ POWER DCA-40SSAI
AC GENERATOR
Generator Assembly.................................................66-69
Control Box Assembly..............................................70-71
Engine & Radiator Assembly....................................72-75
Engine Operating Panel Assembly ...........................76-79
Battery Assembly .....................................................80-81
Muffler Assembly .....................................................82-83
Fuel Tank Assembly .................................................84-85
Enclosure Assembly ................................................86-91
Name Plate And Decals ...........................................92-93
NOTE
Specification and part number
are subject to change without
notice.
PAGE 4 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
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PARTS ORDERING PROCEDURES
I Dealer account number
I Dealer name and address
I Shipping address (if different than billing address)
I Return fax number
I Applicable model number
I Quantity, part number and description of each part
I Specify preferred method of shipment:
UPS Ground
•
UPS Second Day or Third Day*
•
UPS Next Day*
•
Federal Express Priority One (please provide us with your Federal
Express account number)*
•
Airborne Express*
•
Truck or parcel post
•
*Normally shipped the same day the order is received, if prior to 2PM west coast time.
Earn Extra Discounts when
you order by FAX!
All parts orders which include complete part numbers
and are received by fax qualify for the following extra
discounts:
Number of
line items ordered
Additional Discount
1-9 items
3%
10+ items**
5%
only
s
der
ed or
x
a
f
For
Get special freight allowances
when you order 10 or more
line items via FAX!**
Now! Direct TOLL-FREE access
to our Parts Department!
I
UPS Ground Service at no charge for freight
I
PS Third Day Service at one-half of actual freight cost
Toll-free nationwide:
800-421-1244
No other allowances on freight shipped by any other carrier.
**Common nuts, bolts and washers (all items under $1.00 list price)
do not count towards the 10+ line items.
Toll-free FAX:
*DISCOUNTS ARE SUBJECT TO CHANGE*
800/6-PARTS-7 • 800-672-7877
Fax order discount and UPS special programs revised June 1, 1995
DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 5
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RULES FOR SAFE OPERATION
CAUTION:
I
NEVER touch the hot exhaust
manifold, muffler or cylinder. Allow
these parts to cool before servicing
engine or generator.
Failure to follow instructions in this manual
may lead to serious injury or even death!
This equipment is to be operated by trained
and qualified personnel only!This equipment
is for industrial use only.
The following safety guidelines should always be used when
operating the DCA-40SSAI portable generator:
I
I
High Temperatures – Allow the engine to cool before
adding fuel or performing service and maintenance
functions. Contact with hot components can cause serious
burns.
GENERAL SAFETY
I
I
I
DONOToperateorservicethisequipmentbefore
reading this entire manual.
The engine of this generator requires an adequate free
flow of cooling air. Never operate the generator in any
enclosed or narrow area where free flow of the air is
restricted. If the air flow is restricted it will cause serious
damage to the generator or engine and may cause injury
to people.The generator engine gives off DEADLY carbon
monoxide gas.
This equipment should not be operated by
persons under 18 years of age.
NEVER operate this equipment without proper
protective clothing, shatterproof glasses, steel-
toed boots and other protective devices
required by the job.
CAUTION
:
I
Always refuel in a well-ventilated area,
away from sparks and open flames.
I
I
I
NEVER operate this equipment when not feeling
well due to fatigue, illness or taking medicine.
I
Always use extreme caution when
NEVER operate this equipment under the
influence or drugs or alcohol.
working with flammable liquids. When
refueling, stop the engine and allow it
to cool. DO NOT smoke around or near
the machine. Fire or explosion could
result from fuel vapors, or if fuel is spilled
on a hot engine.
NEVER use accessories or attachments, which are not
recommended by MQ Power for this equipment. Damage
to the equipment and/or injury to user may result.
I
NEVER operate the generator in an
I
I
I
Manufacturer does not assume responsibility for any
accident due to equipment modifications.
explosive atmosphere or near combustible
materials. An explosion or fire could result
causing severe bodily harm or even
death.
Whenever necessary, replace nameplate, operation and
safety decals when they become difficult read.
Always check the machine for loosened threads or bolts
before starting.
I
Topping-off to filler port is
dangerous, as it tends to spill fuel.
PAGE 6 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
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RULES FOR SAFE OPERATION
CAUTION
:
CAUTION
:
DO NOT touch or open any of the below
mentioned components while the
generator is running. Always allow
sufficient time for the engine and generator
to cool before performing maintenance.
I
NEVER touch output terminals during operation. This is
extremely dangerous. Always stop the machine when
contact with the output terminals is required.
Radiator
1. Radiator Cap - Removing the radiator cap while the
engine is hot will result in high pressurized, boiling water
to gush out of the radiator, causing severe scalding to
any persons in the general area of the generator.
CAUTION
:
2. Coolant Drain Plug - Removing the coolant drain plug
while the engine is hot will result in hot coolant to gush
out of the coolant drain plug, therefore causing severe
scalding to any persons in the general area of the
generator.
3. Engine Oil Drain Plug - Removing the engine oil drain
plug while the engine is hot will result in hot oil to gush
out of the oil drain plug, therefore causing severe
scalding to any persons in the general area of the
generator.
I
Backfeed to a utility system can cause electrocution
and.or property damage. Do not connect to any
building's electrical system except through an approved
device or after building main switch is opened.
CAUTION
:
Never use damaged or worn cables when
connecting power tools or equipment to the
generator. Make sure power connecting
cables are securely connected to the
generator’s output terminals, insufficient
tightening of the terminal connections may
cause damage to the generator and
electrical shock.
DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 7
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RULES FOR SAFE OPERATION
Battery
I
I
I
I
NEVER Run engine without air filter. Severe engine
damage may occur.
CAUTION
:
Always service air cleaner frequently to prevent carburetor
malfunction.
Never over fill the battery with water above
the upper limit.
Always disconnect the battery before performing service
on the generator.
Always be sure the operator is familiar with proper safety
precautions and operations techniques before using
generator.
The battery contains acids that can cause injury to the eyes
and skin.To avoid eye irritation, always wear safety glasses.
Use well insulated gloves when picking up the battery. Use
the following guidelines when handling the battery:
I
Always store equipment properly when not in use.
Equipment should be stored in a clean, dry location out of
the reach of children.
I
I
I
I
DO NOT leave the generator running in the manual mode
unattended.
DO NOT allow unauthorized people to operate this
equipment.
1. DO NOT drop the battery. There is the possibility of risk
Always read, understand, and follow procedures in
Operator’s Manual before attempting to operate equipment.
that the battery may explode.
2. DO NOT expose the battery to open flames, sparks,
cigarettes etc. The battery contains combustible gases
and liquids. If these gases and liquids come in contact
with a flame or spark, an explosion could occur.
Refer to the Isuzu Engine Owner's Manual for engine
technical questions or information.
Loading and Unloading (Crane)
I
Before lifting, make sure the generator's lifting hook is
secure and that there is no apparent damage to the
generator itself (loose screws, nuts and bolts). If any
part is loose or damaged, please take corrective action
before lifting.
3. Always keep the battery charged. If the battery is not
charged a buildup of combustible gas will occur.
4. Always keep battery charging and booster cables in good
working condition. Repair or replace all worn cables.
5. Always recharge the battery in an open air environment,
to avoid risk of a dangerous concentration of combustible
gases.
I
I
Always drain fuel prior to lifting.
Always make sure crane or lifting device has been
properly secured to the hook of guard frame on generator.
6. In case the battery liquid (dilute sulfuric acid) comes in
contact with clothing or skin, rinse skin or clothing
immediately with plenty of water.
I
I
NEVER lift the machine while the engine is running.
Use adequate lifting cable (wire or rope) of sufficient
strength.
7. In case the battery liquid (dilute sulfuric acid) comes in
contact with your eyes, rinse eyes immediately with
plenty of water, then contact the nearest doctor or hospital,
and seek medical attention.
I
I
I
When lifting the generator, always use the balanced
center-point suspension hook and lift straight upwards.
NEVER allow any person or animal to stand underneath
the machine while lifting.
When loading the generator on a truck, be sure to use
the front and back frame bars as a means to secure the
generator during transport.
PAGE 8 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
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RULES FOR SAFE OPERATION
Transporting
I
I
I
Always shutdown engine before transporting.
Tighten fuel tank cap securely.
Drain fuel when transporting generator over long distances
or bad roads.
I
I
Keep the machinery in proper running condition.
I
I
Always tie-down the generator during transportation by
securing the generator.
Fix damage to the machine immediately and always
replace broken parts.
If generator is mounted on a trailer, make sure trailer
complies with all local and state safety transportation
laws. See page 10 for basic towing procedures.
I
Dispose of hazardous waste properly. Examples of
potentially hazardous waste are used motor oil, coolant,
fuel, and fuel filters.
Emergencies
I
I
DO NOT use plastic containers to dispose of hazardous
waste.
I
Always know the location of the nearest fire extinguisher
and first aid kit. Know the location of the nearest telephone.
Also know the phone numbers of the nearest ambulance,
doctor and fire department.
DO NOT pour waste, oil, coolant or fuel directly onto the
ground, down a drain or into any water source.
DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 9
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DCA-40SSAI —TOWING ANDTRANSPORTATION
Towing Safety Precautions
I
I
ALWAYS attach trailer’s safety chain to bumper of towing
vehicle.
CAUTION :
ALWAYS make sure the vehicle and trailer directional,
backup, brake, and trailer lights are connected and
working properly.
Check with your county or state safety
towing regulations department before towing
your generator.
I
The maximum speed for highway towing is 45 MPH
unless posted otherwise. Recommended off-road towing
is not to exceed 10 MPH or less depending on type of
terrain.
To reduce the possibility of an accident
while transporting the generator on public roads, always
make sure the trailer (Figure 1) that supports the generator
and the towing vehicle are in good operating condition and
both units are mechanically sound.
I
I
I
Place chocked blocks underneath wheel to prevent
rolling, while parked.
Place support blocks underneath the trailer’s bumper to
prevent tipping, while parked.
The following list of suggestions should be used when towing
your generator:
Use the trailer’s hand winch to adjust the height of the
trailer, then insert locking pin to lock wheel stand in place,
while parked.
I
Make sure the hitch and coupling of the towing vehicle
are rated equal to, or greater than the trailer "gross vehicle
weight rating" (GVWR).
I
Avoid sudden stops and starts. This can cause skidding,
or jackknifing. Smooth, gradual starts and stops will
improve gas milage.
I
ALWAYS inspect the hitch and coupling for wear.NEVER
tow a trailer with defective hitches, couplings, chains
etc.
I
I
I
Avoid sharp turns to prevent rolling.
I
I
Check the tire air pressure on both towing vehicle and
trailer. Also check the tire tread wear on both vehicles.
Remove wheel stand when transporting.
DO NOT transport generator with fuel in tank.
ALWAYS make sure the trailer is equipped with a "Safety
Chain".
Figure 1. Generator with Trailer
PAGE 10 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
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DCA-40SSAI —TRAILER-SAFETY GUIDELINES
4.
5.
6.
Frame Length - This measurement is from the ball
hitch to the rear bumper (reflector).
Frame Width - This measurement is from fender to
fender.
Jack Stand - Trailer support device with maximum
pound requirement from the tongue of the trailer.
CAUTION:
ALWAYS make sure the trailer is in good
operating condition. Check the tires for
proper inflation and wear. Also check the
wheel lug nuts for proper tightness.
7. Coupler - Type of hitch used on the trailer for towing.
8. Tire Size - Indicates the diameter of the tire in inches
(10,12,14, etc.), and the width in millimeters
(175,185,205, etc.). The tire diameter must match the
diameter of the tire rim.
Explanation of Chart:
This section is to provide the user with trailer service and
maintenance information. The service and maintenance
guidelines referenced in this section apply a wide range of
trailers. Remember periodic inspection of the trailer will en-
sure safe towing of the equipment and will prevent damage
to the equipment and personal injury.
9. Tire Ply - The tire ply (layers) number is rated in letters;
2-ply,4-ply,6-ply, etc.
10. Wheel Hub - The wheel hub is connected to the trailer’s
axle.
It is the purpose of this section to cover the major mainte-
nance components of the trailer. The following trailer com-
ponents will be discussed in this section:
11. Tire Rim - Tires mounted on a tire rim. The tire rim must
match the size of the tire.
12. Lug Nuts - Used to secure the wheel to the wheel hub.
Always use a torque wrench to tighten down the lug
nuts. SeeTable 4 and Figure 5 or lug nut tightening and
sequence.
13. Axle - Indicates the maximum weight the axle can sup-
port in pounds, and the diameter of the axle expressed
in inches (see Table 3). Please not that some trailers
have a double axle. This will be shown as 2-6000 lbs.,
meaning two axles with a total weight capacity of 6000
pounds.
14. Suspension - Protects the trailer chassis from shocks
transmitted through the wheels. Types of suspension
used are leaf, Q-flex, and air ride.
15. Electrical - Electrical connectors (looms) are provided
with the trailer so the brake lights and turn signals can
be connected to the towing vehicle.
Brakes
Tires
Lug NutTorquing
Suspension
Electrical
Brake Troubleshooting Tables
Use the following definitions with reading Table 1.
1. Fuel Cell - Provides an adequate amount of fuel for the
equipment in use. Fuel cells must be empty when trans-
porting equipment.
2. Braking System - System employed in stopping the
trailer. Typical braking systems are electric, surge, hy-
draulic, hydraulic-surge and air.
3. GVWR- Gross Vehicle Weight Rating (GVWR), is the
maximum number of pounds the trailer can carry, in-
cluding the fuel cell (empty).
16. Application - Indicates which units can be employed
on a particular trailer.
DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 11
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DCA-40SSAI —TRAILER-SPECIFICATIONS
Table 1. Specifications
MODEL
APPLICATION
FUEL
CELL
BRAKE
SYSTEM
GVWR
FRAME
LENGTH
FRAME
WIDTH
JACK
STAND
TRLR-10W
TRLR-10
SDW225,
SGW250,TLW300
NO
NO
1900LBS
1900LBS
1900LBS
2200LBS
2700LBS
2700LBS
2700LBS
7000LBS
7000LBS
7000LBS
7000LBS
10000LBS
11160LBS
14000LBS
18000LBS
18000LBS
30000LBS
30000LBS
96"
96"
96"
85"
50"
50"
50"
42"
800LB.
FULL TILT WHEEL
DCA10, TLG12,
DCA-15
NO
NO
800LB.
FULL TILT WHEEL
TRLR-10XF
TRLR-225W
TRLR-BLW400
TRLR-50X
DCA10, TLG-12,
DCA15, TLW-300
52 GAL
NO
NO
NO
800LB.
FULL TILT WHEEL
WELDERS,
DA7000SS
800LB.
FULL TILT WHEEL
BLW-400
NO
ELECTRIC
NO
W/MAST 154"
W/O 124"
55"
(78" TALL)
800LB.
FULL TILT WHEEL
DCA-25
NO
124"
124"
186"
138"
138"
190"
186"
204"
222"
238"
238"
384"
384"
55"
55"
77"
66"
66"
76"
77"
84"
83"
83"
83"
96"
96"
800LB.
FULL TILT WHEEL
TRLR-50XF
TRLR-70W
DCA-25
41 GAL
NO
NO
800LB.
FULL TILT WHEEL
DCA-45, -60, 70
DCA-45, -60, 70
DCA-45, -60, 70
DCA-100, 125
SURGE
2000LB.
FLAT PAD
TRLR-70X
OPT
SURGE
2000LB.
FLAT PAD
TRLR-70XF
TRLR-100XF
TRLR-85/125
TRLR-150XF
TRLR-220XF
TRLR-300XF
TRLR-400XF
TRLR-600XF
TRLR-800SX
53 GAL
150 GAL
145 GAL
200 GAL
250 GAL
250 GAL
350 GAL
550 GAL
550 GAL
SURGE
2000LB.
FLAT PAD
HYDRAULIC SURGE
HYDRAULIC
HYDRAULIC SURGE
HYDRAULIC SURGE
HYDRAULIC SURGE
ELECTRIC
AIR
2000LB.
FLAT PAD
DCA-85, 100,
125
2000LB.
FLAT PAD
DCA-150, 180
5000 LB.
FLAT PAD
DCA-220
5000 LB.
FLAT PAD
DCA-300
5000 LB.
FLAT PAD
DCA-400
5000 LB.
FLAT PAD
DCA-600, 800
DCA-600, 800
5000 LB.
FLAT PAD
AIR
5000 LB.
FLAT PAD
PAGE 12 — DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01)
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DCA-40SSAI —TRAILER-SPECIFICATIONS
Table 1. Specifications (Con't)
MODEL
COUPLER
TIRES
WHEELS
AXLE
HUBS SUSPENSION
ELECTRICAL
TRLR-10W
2" BALL CLASS
2 ADJUSTABLE
175-13C
13"X4.50"
2200# 2X2
5 LUG
5 LUG
5 LUG
5 LUG
5 LUG
5 LUG
5 LUG
5 LUG
5 LUG
5 LUG
5 LUG
6 LUG
8 LUG
8 LUG
8 LUG
8 LUG
8 LUG
8 LUG
3 LEAF
3 LEAF
3 LEAF
Q FLEX
3 LEAF
4 LEAF
4 LEAF
5 LEAF
5 LEAF
5 LEAF
5 LEAF
7 LEAF
7 LEAF
Q FLEX
Q FLEX
Q FLEX
7 LEAF
AIR-RIDE
4 WIRE LOOM W/
4 POLE FLAT
TRLR-10
TRLR-10XF
TRLR-225W
2"BALL CLASS
2 ADJUSTABLE
175-13C
175-13C
13"X4.5"
13"X4.5"
13X4.5"
13 X 4.5"
13"X4.50"
13"X4.50"
14"X5"
2200#2X2
2200#2X2
2200#2X2
2200#2X2
4 POLE FLAT
4 POLE FLAT
4 POLE FLAT
4 POLE FLAT
2"BALL CLASS
2 ADJUSTABLE
2"BALL CLASS
2 ADJUSTABLE
175-13B
TRLR-BLW
400
2"BALL CLASS
2 ADJUSTABLE
175-13C
TRLR-50X
TRLR-50XF
TRLR-70W
TRLR-70X
TRLR-70XF
2" BALL CLASS
B78-13LRC
B78-13LRC
3500lbs.
2-3/8"
4 POLE RUBBER
FLAT
2" BALL CLASS
3500lbs.
2-3/8"
4 POLE RUBBER
FLAT
2" BALL CLASS
3" ADJUSTABLE
205-14C
BIAS (4)
3500lbs.
3"
4 POLE RUBBER
FLAT
2" BALL CLASS
3" ADJUSTABLE
205-14C
BIAS (4)
14"X5"
3500lbs
3"
4 POLE RUBBER
FLAT
2" BALL CLASS
3" ADJUSTABLE
205-14C
BIAS (4)
14"X5"
3500lbs.
3"
4 POLE RUBBER
FLAT
TRLR-100XF ADJUSTABLE 2-5/6
205-15C
BIAS (4)
14"X5.5"
14"x6"
3500lbs
3"
4 WIRE LOOM
4 WIRE LOOM
4 WIRE LOOM
4 WIRE LOOM
4 WIRE LOOM
4 WIRE LOOM
6 WIRE LOOM
6 WIRE LOOM
OPT 3" EYE
TRLR-85/125 ADJUSTABLE 2-5/6
ST225/75R15D
RADIAL (4)
(2)-6000lbs
(2)-6000lbs
(2)-7000lbs
(2)-6000lbs
(3)-7000lbs.
(3)-10000lbs
(3)-10000lbs
OPT 3" EYE
TRLR-150XF
TRLR-220XF
TRLR-300XF
TRLR-400XF
TRLR-600XF
TRLR-800AR
3" BALL EYE
750-16 E
BIAS (4)
16"X7"
3" EYE
ADJUSTABLE
ST235/85R16E
RADIAL(4)
16"X7"
3" EYE
ADJUSTABLE
ST235/85R16E
RADIAL(6)
16"X7"
3" EYE
ADJUSTABLE
ST235/85R16E
RADIAL(6)
16"X7"
5TH WHEEL
ST215/75R17.5H
RADIAL (8)
16"X7"
5TH WHEEL
ST215/75R17.5H
RADIAL (8)
16"X7"
DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 13
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DCA-40SSAI —TRAILER SAFETY GUIDELINES
Brakes
If your trailer has a braking system, the brakes should be
inspected the first 200 miles of operation. This will allow
the brake shoes and drums to seat properly. After the first
200 mile interval, inspect the brakes every 3,000 miles. If
driving over rough terrain, inspect the brakes more
frequently.
Before any brake synchronizations adjustments can be
made, the trailer brakes should be burnished-in by applying
the brakes 20-30 times with approximately a 20 m.p.h.
decrease in speed, e.g. 40 m.p.h. to 20 m.p.h. Allow ample
time for brakes to cool between application. This allows
the brake shoes to slightly be seated into the brake drum
surface.
Electric Brakes
Electrically actuated brakes (Figure 2) are similar to
hydraulic brakes. The basic difference is that hydraulic
brakes are actuated by an electromagnet.
Listed below are some of the advantages that electric
brakes have over hydraulic brakes:
Figure 2 displays the major electric brake components that
will require inspection and maintenance. Please inspect
these components as required.
Electric Brake Adjustment
Brake system can be manually adjusted to provide
the corrected braking capability for varying road and
load conditions
Brake system can be modulated to provide more or
less braking force, thus easing the brake load on the
towing vehicle
Brake system has very little lag time between the time
the vehicle’s brakes are actuated and the trailer’s brakes
are actuated
Brake system can provide an independent emergency
brake system
1. Place the trailer on jack stands. Make sure the jack
stands are placed on secure level ground.
2. Check the wheel and drum for free rotation.
3. Remove the adjusting hole cover from the adjusting
slot at the bottom brake backing plate.
4. With a screwdriver or standard adjusting tool, rotate
the star wheel of the adjuster assembly to expand the
brake shoes.
5. Adjust the brake shoes outward until the pressure of
the lining against the wheel drum makes the wheel
difficult to turn.
6. Rotate the star wheel in the opposite direction until the
wheel rotates freely with slight lining drag.
7. Replace the adjusting hole cover and lower the trailer
to the ground.
Remember in order to properly synchronize the tow vehicle’s
braking to the trailer’s braking, can only be accomplished
by road testing. Brake lockup, grabbiness or harshness is
due to lack of synchronization between the tow vehicle
and the trailer being towed or under-adjusted brakes.
8. Repeat steps 1 through 6 on the remaining brakes.
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DCA-40SSAI —TRAILER SAFETY GUIDELINES
Figure 2. Electrical Brake Components
Hydraulic/Air/Surge Brakes
Figure 3 below displays the major hydraulic/air/surge brake
Hydraulic brakes (Figure 3) should not require any special
attention with the exception of routine maintenance such
as shoe and lining replacement. These brakes can be
adjusted in the same manner as electric brakes. Brake
lines should be periodically checked for cracks, kinks, or
blockage.
components that will require inspection and maintenance.
Please inspect these components as required using steps
1 through 6 as referenced in the electric brake adjustments
section.
Figure 3. Hydraulic Brake Components
DCA-40SSAI — PARTS AND OPERATION MANUAL — FINAL COPY (07/09/01) — PAGE 15
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