Multiquip Portable Generator dca 60ssai User Manual

PARTS AND OPERATION MANUAL  
PARTS AND OPERATION MANUAL  
MQ POWER  
DCA-60SSAI  
TM  
WHISPERWATT  
GENERATOR  
(Standard)  
PARTS LIST NO. 7451201B  
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  
E-mail:[email protected] www:multiquip.com  
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PAGE 2 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)  
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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-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — 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 Decals ..................................................... 21-22  
DCA -60SSI2 Specifications ................................... 23  
General Information ................................................. 24  
Major Components .................................................. 55  
Dimensions.............................................................. 26  
Control Panel Descriptions ...................................... 28-29  
Engine Operating Panel Descriptions ...................... 30-31  
OutputTerminal Panel Descriptions ......................... 32-33  
Output Amperage Setup .......................................... 34-35  
Output Voltage Setup............................................... 36-39  
Installation ............................................................... 40-41  
Pre Set-up ............................................................... 42-45  
Load Application ...................................................... 46  
Generator Start-up Procedure ................................. 47-49  
Generator Shut-down Procedure.............................. 50  
Maintenance ............................................................ 52-55  
GeneratorWiring Diagram ........................................ 56  
EngineWiring Diagram ............................................ 57  
EngineTroubleshooting ............................................ 58-59  
Generator/EngineTroubleshooting ........................... 60  
Explanation of Codes in Remarks Column .............. 62  
Suggested Spare Parts ........................................... 63  
ISUZU 6BD1 ENGINE  
Cylinder Head Cover Assembly ............................90-91  
Cylinder Head Assembly ......................................92-93  
Cylinder Block Assembly ..................................... 94-97  
Oil Pan and Level Gauge Assembly ..................... 98-99  
Camshaft and Valve Assembly............................. 100-101  
Crankshaft Piston and Flywheel Assembly .......... 102-103  
Timing Gear and Flywheel Housing Assembly .....104-105  
Inlet Manifold Assembly .......................................106-107  
Exhaust Manifold Assembly................................. 108-109  
Ventilation Assembly ............................................ 110-111  
Water Pump and Corrosion Resistor Assembly ....112-113  
Thermostat and Housing Assembly ..................... 114-115  
Engine Water Piping Assembly.............................116-117  
Fan and Fan Belt Assembly ................................. 118-119  
Fuel Injection Assembly .......................................120-121  
Fuel Filter and Bracket Assembly ........................122-123  
Fuel Pump and Pipe Assembly ............................124-125  
Oil Cooler and Oil Filter Assembly ....................... 126-127  
Oil Pump and Oil Strainer Assembly .................... 128-129  
Oil and Vacuum Piping Assembly ........................ 130-131  
Electrical Control Assembly ................................. 132-133  
Starter Components Assembly ............................134-135  
Alternator Components Assembly ........................136-137  
Injection Pump Components Assembly ...............138-141  
Governor Components Assembly .........................142-145  
Feed Pump Assembly .......................................... 146-147  
Misc. Injection Pump Assembly ...........................148-149  
Coupling Assembly............................................... 150-151  
Water Sedimenter Assembly ................................ 152-153  
Switch and Relay Assembly................................. 154-155  
Terms and Condition of Sale — Parts .................. 156  
MQ POWER DCA-60SSAI  
AC GENERATOR  
Generator Assembly................................................ 64-65  
Control Box Assembly............................................. 66-67  
Engine & Radiator Assembly................................... 68-71  
Engine Operating Panel Assembly .......................... 72-75  
Battery Assembly .................................................... 76-77  
Muffler Assembly .................................................... 78-79  
Fuel Tank Assembly ................................................ 80-81  
Enclosure Assembly ............................................... 82-85  
Rubber Seal Assembly ............................................ 86-87  
Name Plate And Decals .......................................... 88-89  
NOTE  
Specification and part number  
are subject to change without  
notice.  
PAGE 4 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)  
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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-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — 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-60SSAI 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  
This equipment should not be operated by  
persons under 18 years of age.  
is restricted it will cause  
serious damage to the  
generator or engine and  
may cause injury to  
people. The generator  
engine gives off DEADLY  
NEVER operate this equipment without proper  
protective clothing, shatterproof glasses, steel-  
toed boots and other protective devices  
required by the job.  
carbon monoxide gas.  
I
I
I
NEVER operate this equipment when not feeling  
well due to fatigue, illness or taking medicine.  
CAUTION  
:
NEVER operate this equipment under the  
influence or drugs or alcohol.  
I
Always refuel in a well-ventilated area,  
away from sparks and open flames.  
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
Always use extreme caution when  
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.  
I
I
I
Manufacturer does not assume responsibility for any  
accident due to equipment modifications.  
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
NEVER operate the generator in an  
explosive atmosphere or near combustible  
materials. An explosion or fire could result  
causing severe bodily harm or even  
death.  
I
Topping-off to filler port is  
dangerous, as it tends to spill fuel.  
PAGE 6 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)  
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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  
:
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.  
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.  
CAUTION  
:
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
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  
generators output terminals, insufficient tightening of the  
terminal connections may cause damage to the generator  
and electrical shock.  
DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — 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  
precaution s 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  
Operators 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-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)  
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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-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 9  
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DCA-60SSAI TOWING RULES FOR SAFE OPERATION  
Towing Safety Precautions  
I
I
ALWAYS attach trailers 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 trailers bumper to  
prevent tipping, while parked.  
The following list of suggestions should be used when towing  
your generator:  
Use the trailers 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 jack-knifing. 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-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)  
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DCA-60SSAI 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.  
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 trailers  
axle.  
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.  
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.  
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:  
„
„
„
„
„
„
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-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 11  
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DCA-60SSAI 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-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)  
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DCA-60SSAI 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-60SSAI PARTS AND OPERATION MANUALFINAL COPY (09/15/01) PAGE 13  
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DCA-60SSAI 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  
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„
„
„
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 vehicles brakes are actuated and the trailers 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 vehicles  
braking to the trailers 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.  
PAGE 14 DCA-60SSAI PARTS AND OPERATION MANUALFINAL COPY (09/15/01)  
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